Coating system and method

ABSTRACT

An atomizing spray device includes a housing having plural inlets and one or more outlets fluidly coupled with each other by an interior chamber. The inlets include a first inlet shaped to receive a first fluid and a second inlet shaped to receive a slurry of ceramic particles and a second fluid. The interior chamber in the housing is shaped to mix the first fluid received via the first inlet with the slurry received via the second inlet inside the housing to form a mixture in a location between the inlets and the one or more outlets. The interior chamber in the housing also is shaped to direct the mixture formed inside the housing as droplets outside of the housing via the one or more outlets such that, based on a discharged amount of the first fluid in the droplets, the first fluid promotes evaporation of the second fluid as the droplets traverse from the housing toward a surface of a component.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.15/460,729, filed 16 Mar. 2017 (now U.S. Pat. No. 10,589,300, issued 17Mar. 2020), which is a continuation-in-part of U.S. patent applicationSer. No. 15/368,242, filed 2 Dec. 2016 (now U.S. Pat. No. 10,265,725,issued 23 Apr. 2019), and U.S. patent application Ser. No. 15/368,185,filed 2 Dec. 2016 (now U.S. Pat. No. 10,384,808, issued 20 Aug. 2019),the entire disclosures of which are incorporated herein by reference.

FIELD

The subject matter described herein relates to engine maintenance.

BACKGROUND

Turbine engines in commercial aircraft have routine maintenanceschedules to reduce downtime of the engines and systems (e.g., vehicles)that rely on continued operation of the engines. Different componentsand features of the engine react differently to engine wear and use overtime, depending on factors such as the extent of use and environmentalconditions to which the engine is exposed.

A thermal barrier coating may be used in the turbine engine to protectthe engine from heat within the engine. Over time, thermal barriercoatings degrade as a result of spallation and other damage, such asexposure to exhaust heat wearing down the coatings. As the thermalbarriers degrade, the turbines are more susceptible to failures and thecoatings may need to be restored or replaced. Typically, a thermalbarrier coating is restored at regularly scheduled maintenance intervalsby disassembling the turbine engine so that a restorative thermalbarrier coating can be applied.

This maintenance of the engine results in significant down time andexpense. The thermal barrier coating may not wear and degrade in thesame manner for each individual aircraft or system that includes anengine with a thermal barrier coating. Thus, a thermal barrier coatingmay need to be restored at intervals that do not coincide with theregularly scheduled maintenance schedule of the engine or aircraft. Theend result is either reduced engine performance resulting from a coatingin use that needs to be restored, or unnecessary down time spentrestoring a coating that does not need to be restored.

Atomizing spray devices are utilized in many different applications toapply coatings onto machinery such as engines, such as thermal barriercoatings. Typically, the thermal barrier coating is restored bydisassembly of the turbine engine so that a restorative thermal barriercoating can be applied. This is problematic where the engine is beingutilized as the amount of downtime required for disassembly greatlyimpacts costs and efficiencies of operating the engine (or systems thatrely on operation of the engine).

BRIEF DESCRIPTION

In one embodiment, an atomizing spray device includes a housing havingplural inlets and one or more outlets fluidly coupled with each other byan interior chamber. The inlets include a first inlet shaped to receivea first fluid and a second inlet shaped to receive a slurry of ceramicparticles and a second fluid. The interior chamber in the housing isshaped to mix the first fluid received via the first inlet with theslurry received via the second inlet inside the housing to form amixture in a location between the inlets and the one or more outlets.The interior chamber in the housing also is shaped to direct the mixtureformed inside the housing as droplets outside of the housing via the oneor more outlets such that, based on a discharged amount of the firstfluid in the droplets, the first fluid promotes evaporation of thesecond fluid as the droplets traverse from the housing toward a surfaceof a component.

In one embodiment, a method includes receiving a first fluid into ahousing of an atomizing spray device through a first inlet of thehousing, receiving a slurry of ceramic particles and a second fluid intothe housing of the atomizing spray device through a second inlet of thehousing, mixing the first fluid and the slurry in an interior chamber ofthe housing of the atomizing spray device to form a mixture in alocation between the first and second inlets and one or more outlets,and directing the mixture outside of the housing of the atomizing spraydevice as droplets via the one or more outlets such that, based on adischarged amount of the first fluid in the droplets, the first fluidpromotes evaporation of the second fluid as the droplets traverse fromthe housing toward a surface of a component.

In one embodiment, an atomizing spray device includes a housing havingplural inlets through a first surface of the housing and one or moreoutlets through a different, second surface of the housing. The housingincludes an interior chamber that fluidly couples the inlets with theone or more outlets. The inlets include a first inlet shaped to receivea first fluid and a second inlet shaped to receive a slurry of ceramicparticles and a second fluid. The interior chamber in the housing isshaped to mix the first fluid received via the first inlet with theslurry received via the second inlet inside the housing to form amixture in a location between the inlets and the one or more outlets.The interior chamber in the housing also is shaped to direct the mixtureformed inside the housing as droplets outside of the housing via the oneor more outlets such that, based on a discharged amount of the firstfluid in the droplets, the first fluid promotes evaporation of thesecond fluid as the droplets traverse from the housing toward a surfaceof a component.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic diagram of a control system for determiningcoating restoration maintenance in accordance with one embodiment;

FIG. 2 is a schematic diagram of a coating restoration system;

FIG. 3 illustrates a flow chart of a method for determining maintenancefor a turbine engine;

FIG. 4 illustrates a flow chart of a method of restoring a coating;

FIG. 5 is a schematic diagram of a coating system;

FIG. 6 is a perspective view of an atomizing spray device in accordancewith one embodiment;

FIG. 7 is a sectional view of the atomizing spray device of FIG. 6 takenalong the line 7-7 shown in FIG. 6;

FIG. 8 is a cut away plan view of the atomizing spray device of FIG. 6;

FIG. 9 is a perspective view of an atomizing spray device in accordancewith one embodiment;

FIG. 10 is a sectional view of the atomizing spray device of FIG. 9taken along the line 10-10 shown in FIG. 9;

FIG. 11 is a cut away plan view of the atomizing spray device of FIG. 9;

FIG. 12 is a perspective view of an atomizing spray device in accordancewith one embodiment;

FIG. 13 is a sectional view of the atomizing spray device of FIG. 12taken along the line 13-13 shown in FIG. 12;

FIG. 14 is a cut away plan view of the atomizing spray device of FIG.12;

FIG. 15 is a perspective view of an atomizing spray device in accordancewith one embodiment;

FIG. 16 is a sectional view of the atomizing spray device of FIG. 15taken along the line 16-16 shown in FIG. 15;

FIG. 17 is a cut away plan view of the atomizing spray device of FIG.15;

FIG. 18 is a prospective view of an atomizing spray device in accordancewith one embodiment;

FIG. 19 is a sectional view of the atomizing spray device of FIG. 18taken along the line 19-19 shown in FIG. 18;

FIG. 20 is a cut away plan view of the atomizing spray device of FIG.18;

FIG. 21 is a flow chart of a method of coating a surface utilizing anatomizing spray device

FIG. 22 illustrates a perspective view of another embodiment of anatomizing spray device;

FIG. 23 illustrates a cross-sectional view of the atomizing spray deviceshown in FIG. 22;

FIG. 24 illustrates a cross-sectional view of the atomizing spray deviceshown in FIG. 22;

FIG. 25 illustrates a perspective view of another embodiment of anatomizing spray device;

FIG. 26 illustrates a cross-sectional view of the atomizing spray deviceshown in FIG. 25;

FIG. 27 illustrates a cross-sectional view of the atomizing spray deviceshown in FIG. 25;

FIG. 28 illustrates a perspective view of another embodiment of anatomizing spray device;

FIG. 29 illustrates a cross-sectional view of the atomizing spray deviceshown in FIG. 28;

FIG. 30 illustrates a cross-sectional view of the atomizing spray deviceshown in FIG. 28;

FIG. 31 illustrates a perspective view of another embodiment of anatomizing spray device;

FIG. 32 illustrates a cross-sectional view of the atomizing spray deviceshown in FIG. 31;

FIG. 33 illustrates a cross-sectional view of the atomizing spray deviceshown in FIG. 31;

FIG. 34 illustrates a perspective view of another embodiment of anatomizing spray device;

FIG. 35 illustrates a cross-sectional view of the atomizing spray deviceshown in FIG. 34; and

FIG. 36 illustrates a cross-sectional view of the atomizing spray deviceshown in FIG. 34.

DETAILED DESCRIPTION

A control system has one or more engine controllers that are configuredto provide an analytics-based engine to restore protective coatings,such as thermal barrier coatings, on turbine components. The one or moreengine controllers use engine parameters such as engine operating data,data and information received from a monitoring system or enginemonitoring controller, data and information inputted into the one ormore controllers of a coating restoration system, data and informationreceived from an auxiliary control controller or system such as avehicle control system (e.g., of an aircraft or other type of vehicle),to identify coating degradation and to determine when to perform acoating restoration procedure.

The control system monitors engine performance parameters or operationalparameters. Responsive to detection of degradation based on theseparameters, one or more coatings within the engine are restored whilethe engine is still in an installed configuration with reduceddisruption to the operation of the powered system in which the engine isdisposed. The installation can occur during an on-wing configuration foran aircraft engine, or in a field installation for an industrial powerturbine.

The one or more engine controllers are configured to communicate withone or more controllers of a coating restoration system and/or determinewhen a coating restoration system is to perform the restoration. Thecoating restoration system includes a mobile supply unit and a spraynozzle coupled to the supply unit. The spray nozzle provides the coatingin a slurry form onto components inside the engine. The mobile supplyunit of the coating restoration system could include a power supply, anair supply, a water supply, and a coating restoration system mounted toa transport vehicle. The coating restoration application system suppliesand stores the restoration coating agent so that the agent can bedelivered to the spray nozzle for application in the turbine engine. Themobile supply unit for providing the coating restoration could be in theback of a truck; the mobile supply unit may be incorporated into a workcart, trailer, or other type of vehicle or support structure.

The one or more engine controllers are in communication with componentsof the gas turbine engines and the coating restoration system bycommunication links (e.g., including wired and/or wireless, direct orindirect, connections). The control system also includes a monitoringsystem that is in communication with the one or more engine controllers.The monitoring system has an engine performance monitor that monitorsengine use data such that the one or more engine controllers can use thedata to determine or predict when a coating restoration of a componentsuch as a turbine engine should be performed. The engine use data caninclude data including full flight and full service exposure data forthe turbine engine, the environmental conditions in which the turbineengine has operated and the like. The one or more engine controllers areconfigured to determine the efficacy of a selected or recommendedcoating restoration procedure. The one or more engine controllers canalso determine a coating restoration schedule based on a specifiedobjective (e.g., prolong engine life, improve performance, or improveefficiency), based on historical engine data and/or other engineoperational data. The one or more engine controllers make thedeterminations by making calculations using an algorithm, comparing datato historical engine data in a look-up table, or the like.

The control system comprises one or more hardware components, softwarecomponents or computer-executable components and data structuresincluding a maintenance determination routine. The one or more enginecontrollers interface with the monitoring system to determine when toapply one or more additives to a thermal barrier coating to restore thecoating. The one or more engine controllers make determinations of whento apply the one or more additives based on data and informationreceived from the monitoring system. The one or more engine controllersoptionally estimate an improved or increased useful life span or servicelife of the coating or engine resulting from restoration of the thermalbarrier coating.

The one or more engine controllers utilize the engine performanceinformation generated by the engine performance monitor to determinewhen to restore a coating in order to maintain or improve theperformance of an engine system. If performance of the engine isseverely degraded, the one or more engine controllers are configured toinitiate a coating restoration event. If an engine is operatingnormally, the one or more engine controllers are configured to determineone or more future coating restorations for the engine at time intervalsbased on a number of coating restoration schedule criteria. Thesecriteria include usage data (e.g., how often the engine is scheduled orexpected to be used, flight or other travel plans of a vehicle that ispropelled by operation of the engine, operating conditions of the engine(e.g., short or long duration missions, altitude, humidity, frequency ofaccelerations versus cruising segments, etc.), characteristics of thecoating restoration technique, and the like.

The one or more engine monitoring controllers receive the operationalinformation from an engine performance monitor that indicates the usageof the engine. The one or more engine monitoring controllers can be theengine controller of an aircraft or other vehicle. The one or moreengine monitoring controllers may be a Full Authority Digital EngineController (FADEC), a component thereof, or a separate module incommunication with a FADEC (e.g., via one or more electroniccommunication links or networks). Optionally, the monitoring systemincludes an on-board engine monitor, of a range of characteristics, suchas the frequency of data acquisition.

The one or more engine monitoring controllers also include hardware,firmware, and/or software components that are configured to perform arange of functions such as communicating and utilizing information anddata, making determinations including calculation based on informationand data and the like similar to the one or more engine controllers. Theone or more engine monitoring controllers include one or more processors(e.g. one or more microprocessors, microcontrollers, digital signalprocessors, etc.), memory, and an input/output (I/O) subsystem. The oneor more engine monitoring controllers can be a laptop computer, ormobile device (e.g., a tablet computer, smart phone, body-mounted deviceor wearable device, etc.), a server, an enterprise computer system, anetwork of computers or the like.

The input and output subsystems of the one or more engine monitoringcontrollers are communicatively coupled to hardware, firmware, and/orsoftware components, including a data storage device, a display, a userinterface subsystem, a communication subsystem, the engine performancemonitor of the monitoring system and the one or more engine coatingcontrollers. Portions of the engine performance monitor and the one ormore controllers of the control system may reside at least temporarilyin the data storage device and/or other data storage devices that arepart of a fleet management system.

The communication subsystem of the one or more engine monitoringcontrollers connects the one or more engine monitoring controllers toother computing devices and/or systems by one or more networks. Thenetwork(s) may be a cellular network, a local area network, a wide areanetwork (e.g., Wi-Fi), a cloud, a virtual personal network (e.g., VPN),an Ethernet network, and/or a public network such as the Internet. Thecommunication subsystem may, alternatively or in addition, enableshorter-range wireless communications between the one or more enginemonitoring controllers and other computing devices, using, for example,Bluetooth and/or other technology. Accordingly, the communicationsub-system may include one or more optical, wired and/or wirelessnetwork interface subsystems, cards, adapters, or other devices, as maybe needed pursuant to the specifications and/or design of the particularengine monitoring controller.

The control system can also include one or more fleet operationscontrollers that are in communication with the one or more enginecontrollers such that scheduling determinations are communicated to theone or more fleet operations controllers. Thus, in addition to singleengine coating restoration schedule generation, schedules for fullfleets of engines or vehicles also may be generated. A communicationsystem of the one or more engine controllers communicates outputs of oneor more of the engine performance monitor, the one or more enginemonitoring controllers and/or the one or more engine controllers to theone or more fleet operations controllers and/or the one or morecontrollers of the coating restoration system. Portions of engine healthdata and/or coating restoration schedule data, may be supplied to theone or more fleet operations controllers and/or the one or morecontrollers of the coating restoration system. Therefore, the one ormore fleet operations controllers are configured to manage turbineengine coating restoration for a fleet of aircraft.

The one or more engine monitoring controllers compare the real-timeengine operating conditions to historical data of similar engines thatare operating appropriately. By monitoring historical operational dataof the engine in a test cell or of similar engines that are operatingappropriately, an engine profile is developed over time usingmodel-based control algorithms. Based on the comparison of the real-timeoperating conditions to the engine profile, the one or more monitoringengine controllers or the one or more engine monitoring controllerspredict or determine the engine performance at a particular time.Therefore, after an engine is built, the engine is tested in a test cellto make sure that it meets the performance requirements to ensure theengine is operating normally before use in the field. The data for eachengine is acquired in a test cell and then incorporated into themodel-based control algorithm so the control algorithm can determine anengine profile.

This test information for specific engines is used to build the controlalgorithms, and then, on-wing, the measured engine output is compared tothis engine profile at a specific point in the engine life that is underconsideration. Thus, the turbine parameters such as temperature andturbine component temperatures can be measured in a test cell and thesemeasurements can be compared with subsequent on-wing temperaturemeasurements. If the difference between the measurements obtained in thetest cell and the measurements obtained on-wing) exceeds certainprescribed values, then the one or more engine controllers or one ormore engine monitoring controllers are configured to determine that theturbine temperature is deteriorating over time, and a coatingrestoration is required. A predetermined range can be set for eachparameter or combination of parameters. Then based on whether theparameter, combination of parameters, calculated parameters or the like,fall within the predetermined range, the one or more engine controllersdetermines when to restore the coatings, such as by scheduling a timefor restoration of the coatings.

The one or more controllers of the coating restoration system can be oneor more computing devices configured to manage engine coatingrestoration services. The one or more controllers of the coatingrestoration system are operated by an engine coating restorationservice, such as at an A check, C check, or procedure at an airport. Theone or more controllers of a coating restoration system is incommunication with all of the other controllers of the control system,including the one or more engine controllers, one or more fleetoperations controllers, and the one or more engine monitoringcontrollers. The one or more controllers of a coating restoration systemincludes an engine coating restoration history database and a coatingrestoration parameters database. The engine coating restoration databasestores information related to the coating restoration history of theturbine engine system, such as, when was the date of the last coatingrestoration of the turbine engine and what coating restoration wasperformed.

The term “database” may refer to, among other things, a computerizeddata structure capable of storing information for easy retrieval (e.g.,a keyword search) or a computer program command. Portions of eachdatabase may be embodied as, for example, a file, a table, or adatabase. While not specifically shown, the fleet management system mayinclude other computing devices (e.g., servers, mobile computingdevices, etc.), which may be in communication with each other and/or theother controllers in the control system.

The engine coating restoration history can also be stored on the enginemaintenance history database. The coating restoration parametersdatabase includes information related to the coating restorationregimens available to be used to restore a particular turbine engine,such as data on all available coating restoration regimens, whichcoating restoration regimens are available at which locationsgeographically, whether a coating restoration crew at a particularlocation is available to perform a coating restoration, and the like.All historical data stored at the one or more controllers of the coatingrestoration system is communicated to all the controllers within thecontrol system to be utilized in determinations, calculations,algorithms and as otherwise needed by the controllers within the controlsystem.

The one or more controllers of the coating restoration system obtain andstore historical data about the engine or the coating restorationhistory of the engine. This is through data inputted into the one ormore controllers and data determined in real-time and stored within thememories of the one or more controllers. The one or more controllers ofthe coating restoration system are configured to use historical data todetermine an engine coating restoration scheme for the operator. The oneor more controllers of the coating restoration system communicate withthe other controllers in the control system to determine when to restorea coating, such as by scheduling maintenance intervals, based uponcertain parts or modules of the turbine engine that need replacement.Thus, the one or more controllers of the coating restoration system areconfigured to determine the amount of restoration required for anindividual component or module. Consequently, the one or morecontrollers of the coating restoration system are configured todetermine if an engine merely needs a minor overhaul/restorationprocedure, and based on the restoration required the one or morecontrollers of the coating restoration system initiate a coatingrestoration. Thus, the engine coating or coatings are restored and theengine is quickly returned to service, thereby extending the efficiencyof the engine until a major overhaul is required.

The one or more controllers of the coating restoration system monitormultiple parameters of the engine including and in addition to thehistorical data. Such parameters of the engine include one or more of anengine exhaust temperature, a condition of the coating of the engine,engine fuel flow, compressor exit pressure, compressor exit temperature,engine derating, engine speed, engine cycles, engine power use,auxiliary power use, environmental conditions, ambient airplanetemperature or dates of engine use. The condition of the coating may beor represent the presence or absence of spalling in the coating, and/oran amount (e.g., number) of spalling or locations of spalling. Theengine derating may occur when the output of the engine is less than adirected output. For example, an engine that remains at the samethrottle position may derate when the power output by the enginedecreases (while remaining at the same throttle position). The number ofengine cycles represents the number of times that the engine is turnedon from an inactive or off state, the engine operates for a period oftime to perform work, and the engine is then deactivated or turned to anoff state. The auxiliary power use may indicate how much work performedby the engine (e.g., how much current generated by operation of theengine) is used for auxiliary power consumption, such as for poweringloads that do not propel a vehicle. The environmental conditions mayindicate the presence (or absence) of dust in the environment in whichthe engine operates, and/or the ambient temperatures in which the engineoperates.

Optionally, the condition of the coating may be altered or may otherwiseimpact how and/or when the additive is sprayed onto the component. Forexample, if the component has a new (e.g., not used in the field)thermal barrier coating, the coating may need to be roughened and madeless smooth in order to ensure that the sprayed additive adheres to thesurface. If the component is a fielded part of an engine and/or isundergoing an overhaul procedure, then there may not be a need toroughen the surface. This could include a fielded part in an engine thatis still on the wing of an aircraft or in the field, a repaired part inan engine or component in an overhaul shop, or the like. Some surfacesmay require cleaning prior to spraying the additive onto the surfaces.For example, a part with a thermal barrier coating having dust on thecoating may need to be cleaned prior to spraying the additive onto thecoating.

Other parameters may include operational parameters indicative ofoperations or work performed by the engine or components of the engine.In one embodiment, the operational parameters may indicate thetemperature, air flow, time of usage, etc., of hot gas components of theengine, such as that of a combustor, turbine blade, turbine vane,turbine vane, turbine shroud, and/or combustor fuel nozzle.

Different parameters may impact when the additive is to be added to thecoating during restoration of the coating in different ways. Forexample, hotter engine exhaust temperatures may require application ofthe additive sooner than for cooler engine exhaust temperatures. Thepresence of spalling and/or a greater amount or degree of spalling mayrequire application of the additive sooner than for an absence orsmaller amount or degree of spalling. Greater amounts of fuel flowing tothe engine may require application of the additive sooner than forlesser amounts of fuel flowing to the engine. Increased compressor exitpressures and/or temperatures may require application of the additivesooner than for smaller or cooler compressor exit pressures and/ortemperatures. Derating of the engine may indicate that application ofthe additive needs to occur sooner than for engines that do not derateor that derate by a lesser amount. Engines operating at faster enginespeeds and/or over more engine cycles may require application of theadditive to the coating sooner than for slower engine speeds and/orfewer engine cycles. Engines producing greater amounts of power (e.g.,relative to a designated threshold) may require application of theadditive to the coating sooner than for engines producing lesser amountsof power. Engines that operate to power greater amounts of auxiliaryloads may require application of the additive to the coating sooner thanfor engines powering less or fewer auxiliary loads.

The one or more controllers of the coating restoration system areconfigured to issue a prompt or notification in order to prevent theoccurrence of a restoration cycle (e.g., an event whereby at least partof the coating is restored by applying an additive to the coating), ifthe one or more controllers of the coating restoration system determinethat removal of the engine from service is imminent (e.g., for regularlyscheduled required maintenance). The one or more controllers of thecoating restoration system include data in a database or memoryregarding the date on which predetermined maintenance is to occur. Theone or more controllers of the coating restoration system then compare adate of maintenance determined as a result of system parameters and ifthe date falls within a predetermined range, such as one month, of thedate of the predetermined maintenance, the one or more controllers ofthe coating restoration system are configured to cancel the determineddate of maintenance.

The maintenance includes restoring a coating at different points in theoperational life of the engine that results in different prolonged lifeof the coating. In one embodiment, an additive is applied to the coatingto extend the life span of the engine or coating to 100% or more (e.g.,of the original life span of the engine or coating) compared to if norestorative coating was provided. In another embodiment, after some lifespan, the additive is applied to extend engine life by 25% the initiallife span. Otherwise if applied after some small spalling, life can beextended by 10% the life span. Alternatively, if the restorative coatingis applied after large spalling, an additional life span can be added asa result of the coating.

Thus, the one or more controllers of the coating restoration systemcoordinate coating restoration cycles with other maintenance schedulesas well as operational schedules. The one or more controllers of thecoating restoration system are configured to establish the bestvariation of cycle times in which the parameters of engine coatingrestoration are determined, including the time interval between coatingrestoration(s), the duration of coating restoration(s), the particularmixture or composition of the coating restoration solution, and thelike. The one or more controllers of the coating restoration system areconfigured to establish a predictive coating restoration schedule basedon the historical data. The predictive coating restoration schedule canthen be used by the engine manufacturer in order to better predictengine coating restoration as a function of minor and major overhaulintervals.

The coatings described herein are restored by applying one or moreadditives to the coatings, which optionally are referred to assolutions, agents, protective agents, or barrier coatings. The additivesprotect underlying thermal barrier coatings from attacks by mixedcalcium-magnesium-aluminum-silicon-oxide systems (Ca—Mg—Al—Si—O),hereafter referred to as “CMAS.” Environmental contaminant compositionsof particular concern are those containing oxides of calcium, magnesium,aluminum, silicon, and mixtures thereof; dirt, ash, and dust ingested bygas turbine engines, for instance, are often made up of such compounds.These oxides often combine to form CMAS. At high turbine operatingtemperatures, these environmental contaminants can adhere to the hotthermal barrier coating surface, and cause damage to the thermal barriercoating. For example, CMAS can form compositions that are liquid ormolten at the operating temperatures of the turbines. The molten CMAScomposition can dissolve the thermal barrier coating, or can fill itsporous structure by infiltrating the pores, channels, cracks, or othercavities in the coating. Upon cooling, the infiltrated CMAS compositionsolidifies and reduces the coating strain tolerance, thus initiating andpropagating cracks that may cause delamination and spalling of thecoating material. This may further result in partial or complete loss ofthe thermal protection provided to the underlying metal substrate of thepart or component. Further, spallation of the thermal barrier coatingmay create hot spots in the metal substrate leading to prematurecomponent failure. Premature component failure can lead to unscheduledmaintenance as well as parts replacement resulting in reducedperformance, and increased operating and servicing costs.

The additives applied to the thermal barrier coatings at times orinstances determined by the systems and methods described herein canprevent or reduce the negative impact of CMAS attack by reacting withthe existing layer of environmental contaminant compositions on thesurface and/or by reacting with additional CMAS deposits formed on thechemical barrier coating after subsequent use of the component (e.g.,after operation of an engine containing the component). Additionally,the chemical barrier coating can protect any bond coat, and particularlyany thermally grown oxide on the bond coat, from CMAS attack, fromreactive particle attack, or reactive layer attack. The chemical barriercoating is particularly useful on coating systems that include a thermalbarrier coating after it has been used in service, and may include aplurality of surface-connected voids, such as cracks and porosity, whichprovides a path for CMAS attack, reactive particle attack, or a reactivelayer attack.

In one embodiment, the additives applied to the thermal barrier coatingmay form a chemical barrier coating directly on a layer of environmentalcontaminant compositions (e.g., CMAS deposits). For example, thechemical barrier coating is formed on a layer of environmentalcontaminant compositions without any pre-washing or any otherpre-treatment step in one embodiment. The additives can be appliedwithout the use of any aqueous or organic precursors. The chemicalbarrier coating generally includes at least one protective agent that isreactive with the contaminant compositions. In one embodiment, theadditives are highly reactive to CMAS-type material, such that, attypical temperatures where CMAS is encountered in liquid form, theprotective agent rapidly reacts with the CMAS to form a solid reactionproduct that itself is thermally and chemically stable in the presenceof liquid CMAS, forming a solid-phase barrier against further CMASattack to the underlaying layers (e.g., to the underlying TBC layer).

The additive includes a substance that is reactive with CMAS material.More particularly, a substance is considered suitable as a substance foruse in the additive as described herein if the substance has thecharacteristic property. In certain embodiments, for instance, theprotective agent may chemically reacting with a nominal CMAS liquidcomposition at atmospheric pressure forms a solid, crystalline productthat is outside the crystallization field of this nominal CMAScomposition. Such a solid crystalline product may have a higher meltingtemperature than the nominal CMAS composition so that it remains as asolid barrier to liquid infiltration.

For the purposes of this description, the term “nominal CMAS” refers tothe following composition, with all percentages in mole percent: 41.6%silica (SiO₂), 29.3% calcia (CaO), 12.5% alumina (AlO_(1.5)), 9.1%magnesia (MgO), 6.0% iron oxide (FeO_(1.5)), and 1.5% nickel oxide(NiO). It will be appreciated that the nominal CMAS composition given inthis definition represents a reference composition to define a benchmarkfor CMAS reactivity of the surface in a way that can be compared to theCMAS reactivity of other substances; use of this reference compositiondoes not limit in any way the actual composition of ingested materialthat becomes deposited on the coating during operation which, of course,will vary widely in service.

If a given substance is capable of reacting with molten CMAS having theabove nominal composition, thereby forming a reaction product that has amelting point higher than about 1200° C., is crystalline, and is outsidethe crystallization field of this nominal CMAS composition, then thesubstance may be useful in the protective agent as described herein. Amaterial is outside the crystallization field of the nominal CMAScomposition if it is not included in the set of crystalline phases thatcan be formed from combinations of the component oxides of the CMAScomposition. Thus, a material that includes a rare-earth element, suchas ytterbium, for instance, would be outside the crystallization fieldof the nominal CMAS composition because none of the component oxides ofthe nominal CMAS includes ytterbium. On the other hand, a reactive agentthat exclusively employs one or more of the other components of thenominal CMAS composition, such as aluminum oxide, would not form aproduct outside the crystallization field of nominal CMAS. Use of aprotective agent substance that promotes formation of reaction productwith CMAS outside the crystallization field of the CMAS may result infaster reaction kinetics with CMAS under some circumstances, and ifreaction kinetics can be accelerated, then ingress of molten CMAS priorto reaction and solidification desirably may be reduced.

In some embodiments, the protective agent includes a rare-earth oxide,that is, an oxide compound that includes a rare-earth element as one ofits constituent elements. As used herein, the terms “rare-earth” and“rare-earth element” are used interchangeably, and encompass elements ofthe lanthanide series, yttrium, and scandium. For example, in someembodiments, the oxide includes lanthanum, neodymium, erbium, cerium,gadolinium, or combinations including any one or more of these. Certaincomplex oxides, that is, oxide compounds that include more than onemetal element constituent, have been shown in some circumstances toprovide comparatively high reactivity with liquid CMAS. In particularembodiments, the oxide is a complex oxide that includes a rare-earthelement and a transition metal element, such as zirconium, hafnium,titanium, or niobium, along with combinations of these. Zirconates,hafnates, titanates, and niobates that include lanthanum, neodymium,cerium, and/or gadolinium are examples of such complex oxide. Aparticular example is gadolinium zirconate. For example, the protectiveagents may include, in particular embodiments, alpha-Al₂O₃, 55YSZ,GdAlO₃, SrGd₂Al₂O₇ (“SAG”), etc., and combinations thereof.

The additive can be applied via a variety of methods, including usingthe systems and atomizing spray nozzles described herein.

One turbine engine considered is a multiple shaft turbofan gas turbineengine. The aspects of the present disclosure are applicable to turbineengines in general. Other types of turbine engines include turboprop andturboshaft systems, as well as turbine engines designed fornon-aerospace applications. In the turbine engine, a fan (e.g., a fan,variable pitch propeller, etc.) draws air into the engine.

FIG. 1 is a schematic diagram of a control system 100 for maintaining acomponent 102 such as an engine of a powered system 106. In oneembodiment, the component 102 is an engine on a wing 104 of an aircraft,but optionally may be an engine of another vehicle, an engine of astationary power-generating system, or another type of component. Thecontrol system 100 includes one or more engine controllers 110. Theengine controller 110 can be of any type, including but not limited to acomputer, computing device, laptop computer, mobile device, tabletcomputer, smart phone, body-mounted device, wearable device, server,enterprise computer system, network of computers, or the like. Theengine controller 110 includes one or more processors 112 that can alsobe of any type, including but not limited to a controller,microprocessor, microcontroller, digital signal processor, and the likethat can receive, determine, compute and transmit information.

The processor 112 can have or operate based on algorithms and look-uptables inputted therein through programming or the like. In this manner,the processor 112 can make calculations based on parameters of theengine 102 and aircraft or compare such parameters to the look-up tablesto make determinations. The processor 112 is in communication with amemory 114 that contains a database of information that is eitherinputted into the controller 110, determined by the processor 112 of thecontroller 110, or communicated from another controller or device, to bestored within the memory 114. The processor 112 and memory 114 are alsoin communication with a communication subsystem 116 that has input andoutput subsystems 118 and 120 to receive and transmit information anddata for the controller 110. The communication subsystem 116 connectsthe one or more engine controllers 110 to other controllers and/orsystems by one or more networks 122.

The network(s) 122 may be a cellular network, a local area network, awide area network (e.g., Wi-Fi), a cloud, a virtual personal network(e.g., VPN), an Ethernet network, and/or a public network such as theInternet. The communication subsystem 116 may, alternatively or inaddition, enable shorter-range wireless communications between the oneor more engine monitoring controllers and other computing devices,using, for example, Bluetooth and/or other technology. Accordingly, thecommunication sub-system 116 may include one or more optical, wiredand/or wireless network interface subsystems, cards, adapters, or otherdevices, as may be needed pursuant to the specifications and/or designof the engine controller.

A display module 124 is also in communication with the processor 112,memory 114 and communication subsystem 116. The display module 124typically is a screen that displays information retrieved from theprocessor 112, memory 114 or communication subsystem 116 to conveyinformation to the user.

A user interface subsystem 125 similarly is in communication with theother components of the engine controller 110, including the processor112, memory 114, communication subsystem 116 and display module 124. Inthis manner, a user my input information, data, historical data,algorithms, models and the like into the engine controller 110 andreceive information as requested.

The control system 100 includes a monitoring system 200 that has one ormore an engine monitoring controllers 210 that can be of any type,including but not limited to a computer, computing device, laptopcomputer, mobile device, tablet computer, smart phone, body-mounteddevice, wearable device, server, enterprise computer system, network ofcomputers, or the like. The engine monitoring controller 210 includes aprocessor 212 that can also be of any type, including but not limited toa controller, microprocessor, microcontroller, digital signal processor,and the like that can receive, determine, compute and transmitinformation.

The processor 212 can make calculations based on parameters of theengine 202 and aircraft or compare such parameters to the look-up tablesto make determinations. The processor 212 is in communication with amemory 214 that contains a database of information that is eitherinputted into the controller 210, determined by the processor 212 of thecontroller 210, or communicated from another controller or device, to bestored within the memory 214. The processor 212 and memory 214 are alsoin communication with a communication subsystem 216 that has input andoutput subsystems 218 and 220 to receive and transmit information anddata for the controller 210. The communication subsystem 216 connectsthe one or more engine monitoring controllers to the one or more enginecontrollers 210 and to other controllers and/or systems by one or morenetworks 222.

The network(s) 222 may be a cellular network, a local area network, awide area network (e.g., Wi-Fi), a cloud, a virtual personal network(e.g., VPN), an Ethernet network, and/or a public network such as theInternet. The communication subsystem 216 may, alternatively or inaddition, enable shorter-range wireless communications between the oneor more engine monitoring controllers and other computing devices,using, for example, Bluetooth and/or other technology. Accordingly, thecommunication sub-system 216 may include one or more optical, wiredand/or wireless network interface subsystems, cards, adapters, or otherdevices, as may be needed pursuant to the specifications and/or designof the particular engine controller.

A display module 224 is also in communication with the processor 212,memory 214 and communication subsystem 216. The display module 224typically is a screen that displays information retrieved from theprocessor 212, memory 214 or communication subsystem 216 to conveyinformation to the user.

A user interface subsystem 225 similarly is in communication with theother components of the engine monitoring controller 210, including theprocessor 212, memory 214, communication subsystem 216 and displaymodule 224. In this manner, a user my input information, data,historical data, algorithms, models and the like into the enginemonitoring controller 210 and receive information as requested.

An engine performance monitoring system 226 is also in communicationwith the processor 212, memory 214 and communication subsystem 216 ofthe engine monitoring controller 210. The engine performance monitoringsystem 226 includes sensors 228 and 230 in the engine 102 that measurereal-time parameters of the engine. In one embodiment, sensor 228 is atemperature sensor that measures the air temperature of air entering theengine and sensor 230 is a temperature sensor that measures the airtemperature of the exhaust existing the engine 102. In anotherembodiment, one of the sensors 228 or 230 is a mass flow sensor. Thesensors 228 and 230 take real time measurements that are communicated tothe processor 212 and memory 214 of the engine monitoring controller210.

The engine performance monitoring system 226 in one embodiment monitorsthe condition of the thermal barrier coating of the engine utilizingmethods as presented in U.S. Pat. No. 9,395,301 that is incorporated byreference herein. Thus, the sensors 228 and 230 monitor coatingparameters including temperature at the coating to utilize the methodspresented in the '301 patent.

In this manner, the processor 212 can make determinations such ascalculating fuel efficiency of the engine. Such determinations can thenbe compared to an engine profile created from historical data of similarengines or from test cell data from testing of the engine prior to use.Based on the comparison the processor 212 and thus controller 210determines a date or range of dates for maintaining the engine for theindividual aircraft. Alternatively, the real time measurements, data,information or determination of the one or more engine monitoringcontrollers are communicated to the one or more engine controllers 110for similar determinations and calculations and to determine a date orrange of dates for maintenance for the individual aircraft. Thecommunication between the one or more engine controller 110 and enginemonitoring controller 210 is provided through communication links,including wired and/or wireless, direct or indirect, connections.

The sensors 228 and 230 may include thermocouples that generatepotentials representative of temperatures or changes in temperature inthe air, a thermometer, or another device that can sense temperature andgenerate an output signal to the controller 210 that indicatestemperature. The sensors 228 and 230 may also be a piezoelectric straingauge, a capacitive pressure sensor, an electromagnetic pressure sensor,or other device that can sense pressure of the air and generate anoutput signal to the controller 210 that indicates the pressure. In oneembodiment, one of the sensors 228, 230 or an additional sensor may bean oxygen sensor that measures the amount of oxygen conveyed to theengine. The controller 210 may monitor the rates of air flow through theengine during flight from mass flow sensors that are coupled with orincluded in the engine.

The one or more engine monitoring controllers 210 can be the enginecontroller of the aircraft 106. The one or more engine monitoringcontrollers 210 may be a Full Authority Digital Engine Controller(FADEC), a component thereof, or a separate module in communication witha FADEC (e.g., via one or more electronic communication links ornetworks). Optionally, the monitoring system 226 includes an on-boardengine monitor, of a range of characteristics, such as the frequency ofdata acquisition.

The control system 100 can also optionally include a fleet managementsystem 300 having one or more fleet operations controllers 310. The oneor more fleet operations controllers 310 can be of any type, includingbut not limited to a computer, computing device, laptop computer, mobiledevice, tablet computer, smart phone, body-mounted device, wearabledevice, server, enterprise computer system, network of computers, or thelike. The fleet operations controller 310 includes a processor 312 thatcan also be of any type, including but not limited to a controller,microprocessor, microcontroller, digital signal processor, and the likethat can receive, determine, compute and transmit information.

The processor 312 can have algorithms and look-up tables inputtedtherein through programming or the like. In this manner, the processor312 can make calculations based on parameters of the engine 302 andaircraft or compare such parameters to the look-up tables to makedeterminations. The processor 312 is in communication with a memory 314that contains a database of information that is either inputted into thecontroller 310, determined by the processor 312 of the controller 310,or communicated from another controller or device, to be stored withinthe memory 314. The processor 312 and memory 314 are also incommunication with a communication subsystem 316 that has input andoutput subsystems 318 and 320 to receive and transmit information anddata for the controller 310. The communication subsystem 316 connectsthe one or more fleet operations controller 310 to other controllersand/or systems of the control system by one or more networks 322,including the one or more engine controllers or the one or more enginemonitoring controllers.

The network(s) 322 may be a cellular network, a local area network, awide area network (e.g., Wi-Fi), a cloud, a virtual personal network(e.g., VPN), an Ethernet network, and/or a public network such as theInternet. The communication subsystem 316 may, alternatively or inaddition, enable shorter-range wireless communications between the oneor more engine monitoring controllers and other computing devices,using, for example, Bluetooth and/or other technology. Accordingly, thecommunication sub-system 316 may include one or more optical, wiredand/or wireless network interface subsystems, cards, adapters, or otherdevices, as may be needed pursuant to the specifications and/or designof the particular engine controller.

A display module 324 is also in communication with the processor 312,memory 314 and communication subsystem 316. The display module 324typically is a screen that displays information retrieved from theprocessor 312, memory 314 or communication subsystem 316 to conveyinformation to the user.

A user interface subsystem 325 similarly is in communication with theother components of the fleet operations controller 310, including theprocessor 312, memory 314, communication subsystem 316 and displaymodule 324. In this manner a user my input information, data, historicaldata, algorithms, models and the like into the engine monitoringcontroller 310 and receive information as requested.

By using the one or more fleet operation controllers 310, in addition tosingle engine coating restoration schedule generation, schedules forfull fleets of engines or vehicles may be generated. Portions of enginedata and/or coating restoration schedule data, may be supplied to theone or more fleet operations controllers 310 and/or the one or morecontrollers of a coating restoration system. Therefore, the one or morefleet operations controllers 310 are configured to manage turbine enginecoating restoration for a fleet of aircraft.

In one example, as the controllers 110 and/or 210 determine dates orranges of dates maintenance should occur in individual aircraft, the oneor more fleet operations controllers 310 receive this information for anentire fleet of aircraft. In this manner, the one or more fleetoperation controllers 310 can determine if a predetermined percentage ofthe fleet exceeds a threshold percentage for maintenance down time toreschedule maintenance of at least one aircraft to ensure the properamount of aircraft remain operating within the fleet.

In another example, as the controllers 110 and/or 210 determine dates orranges of dates maintenance should occur in individual aircraft, the oneor more fleet operations controllers 310 receive this information for anentire fleet of aircraft. In this manner, the one or more fleetoperation controllers 310 can utilize an algorithm that utilizes all ofthe flight schedules of all of the aircraft that require maintenance ina given range of dates to determine the location that coatingrestoration for all of the aircraft being restored is to occur to reducedowntime of the aircraft under maintenance.

The control system 100 also includes one or more controllers 410 of acoating restoration system. The one or more controllers 410 of thecoating restoration system can be of any type, including but not limitedto a computer, computing device, laptop computer, mobile device, tabletcomputer, smart phone, body-mounted device, wearable device, server,enterprise computer system, network of computers, or the like. Theengine controller 410 includes a processor 412 that can also be of anytype, including but not limited to a controller, microprocessor,microcontroller, digital signal processor, and the like that canreceive, determine, compute and transmit information.

The processor 412 can have algorithms and look-up tables inputtedtherein through programming or the like. In this manner, the processor412 can make calculations based on parameters of the engine 402 andaircraft or compare such parameters to the look-up tables to makedeterminations. The processor 412 is in communication with a memory 414that contains a database of information that is either inputted into thecontroller 410, determined by the processor 412 of the controller 410,or communicated from another controller or device, to be stored withinthe memory 414.

The memory 414 includes a restoration history database and a coatingrestoration parameters database. The restoration history database storesinformation related to the coating restoration history of the turbineengine system, such as, when was the date of the last coatingrestoration of the turbine engine and what coating restoration wasperformed. The coating restoration parameters database includesinformation related to the coating restoration regimens available to beused to restore a particular turbine engine, such as data on allavailable coating restoration regimens, which coating restorationregimens are available at which locations geographically, whether acoating restoration crew at a particular location is available toperform a coating restoration, and the like.

The processor 412 and memory 414 are also in communication with acommunication subsystem 416 that has input and output subsystems 418 and420 to receive and transmit information and data for the controller 410.The communication subsystem 416 connects the one or more controllers 410of the coating restoration system to the other controllers and systemsby one or more networks 422, including the one or more enginecontrollers, the one or more engine monitoring controllers or the one ormore fleet operations controllers.

The network(s) 422 may be a cellular network, a local area network, awide area network (e.g., Wi-Fi), a cloud, a virtual personal network(e.g., VPN), an Ethernet network, and/or a public network such as theInternet. The communication subsystem 416 may, alternatively or inaddition, enable shorter-range wireless communications between the oneor more engine monitoring controllers and other computing devices,using, for example, Bluetooth and/or other technology. Accordingly, thecommunication sub-system 416 may include one or more optical, wiredand/or wireless network interface subsystems, cards, adapters, or otherdevices, as may be needed pursuant to the specifications and/or designof the particular engine controller.

A display module 424 is also in communication with the processor 412,memory 414 and communication subsystem 416. The display module 424typically is a screen that displays information retrieved from theprocessor 412, memory 414 or communication subsystem 416 to conveyinformation to the user.

A user interface subsystem 425 similarly is in communication with theother components of the one or more controllers 410 of the coatingrestoration system, including the processor 412, memory 414,communication subsystem 416 and display module 424. In this manner auser my input information, data, historical data, algorithms, models andthe like into the one or more controllers 410 of the coating restorationsystem and receive information as requested.

FIG. 2 shows the coating restoration system 450 that is operated by andincludes controller 410. The coating restoration system 450 includes amobile supply unit 452 such as a truck or is incorporated into a workcart, trailer, or other type of vehicle or support structure. The mobilesupply unit 452 includes a power supply 454, an air supply 456, a watersupply 458 and a coating restoration unit 460 mounted on the mobilesupply unit 452. The coating restoration unit 460 includes a rail 462and glider 464 with an attachment mechanism 466 on the glider thatattaches a spray nozzle 468 that receives a slurry and air to output acoating for a component such as a thermal barrier coating. The rail 462and glider 464 system provide for 360° degree movement to coat anysurface of the component. The coating restoration system 450 stores therestoration coating agent so that it can be delivered to the spraynozzle 468 for application in the turbine engine.

The one or more controllers 410 of the coating restoration system 450are operated by an engine coating restoration service, such as at an Acheck, C check, or procedure at an airport. The one or more controllers410 of a coating restoration system 450 is in communication with all ofthe other controllers 110, 210 and 310 of the control system 100. Allhistorical data stored at the one or more controllers 410 of the coatingrestoration system 450 is communicated to all of the controllers 110,210 and 310 within the control system 100 to be utilized indeterminations, calculations, algorithms and as otherwise needed by thecontrollers 110, 210 and 310 within the control system.

The one or more controllers 410 of the coating restoration system 450obtains and stores historical data about the engine or the engine'scoating restoration history. This is through data inputted into the oneor more controllers and data determined in real-time and stored withinthe memories of the one or more controllers 110, 210 and 310. The one ormore controllers 410 of the coating restoration system 450 areconfigured to use the historical data to determine an engine coatingrestoration scheme for the operator. The one or more controllers 410 ofthe coating restoration system 450 communicate with the othercontrollers 110, 210 and 310 in the control system 100 to schedulemaintenance intervals based upon certain parts or modules of the turbineengine that need replacement. Thus, the one or more controllers 410 ofthe coating restoration system 450 are configured to determine theamount of restoration required for an individual component or module.Consequently, the one or more controllers 410 of the coating restorationsystem 450 are configured to determine if an engine 102 merely needs aminor overhaul/restoration procedure, and based on the restorationrequired the one or more controllers 410 of the coating restorationsystem 450 initiate a coating restoration. As a result, the enginecoating or coatings are restored and the engine is quickly returned toservice, thereby extending the engine's efficiency until a majoroverhaul is required.

The one or more controllers 410 of the coating restoration system 450are configured to issue a prompt or notification to prevent theoccurrence of a scheduled coating restoration cycle, if the one or morecontrollers 410 of the coating restoration system 450 determines thatthe engine's removal from service is imminent (e.g., for regularlyscheduled required maintenance). The one or more controllers 410 of thecoating restoration system 450 include data in a database or memoryregarding the date on which predetermined maintenance is to occur. Theone or more controllers 410 of the coating restoration system 450 thencompare a date of maintenance determined as a result of systemparameters and if the date falls within a predetermined range, such asone month, of the date of the predetermined maintenance, the one or morecontrollers 410 of the coating restoration system 450 are configured tocancel the determined date of maintenance.

Thus, the one or more controllers 410 of the coating restoration system450 are configured to coordinate coating restoration cycles with othermaintenance schedules as well as operational schedules. The one or morecontrollers 410 of the coating restoration system 450 are configured toestablish the best variation of cycle times in which the parameters ofengine coating restoration are determined, including the time intervalbetween coating restoration(s), the duration of coating restoration(s),the particular mixture or composition of the coating restorationsolution, and the like. The one or more controllers 410 of the coatingrestoration system 450 are configured to establish a predictive coatingrestoration schedule based on the historical data. The predictivecoating restoration schedule can then be used by the engine manufacturerin order to better predict engine coating restoration as a function ofminor and major overhaul intervals.

FIG. 3 shows a method for determining maintenance of a turbine engine500.

At 502, the measurements of parameters of a turbine engine are taken ina test cell prior to use of the turbine engine. At 504, an engineprofile is formed based the measurements or on historical data ofsimilar engines and inputted or communicated to the controllers of acontrol system.

At 506, a controller monitors parameters of the engine during operation.These parameters can include engine temperature, different airtemperatures at the engine, fuel consumption and the like. At 508, in anembodiment where the engine is on an aircraft, parameters of theaircraft are inputted and communicated to controllers in the controlsystem. These parameters include environmental conditions during flight,flight durations, air speeds and the like.

At 510, a controller makes determinations based on the parameters of theengine and the aircraft (for such an embodiment). Based on thesedeterminations the controller determines a date or a range of dates formaintenance of the engine to restore a coating at 512.

At 514, the determined date or range of dates is communicated to acontroller of a coating restoration system. At 516, the controller ofthe coating restoration system compares the date or dates communicatedto pre-determined maintenance date of the engine to determine if theinitial determined date or range of dates falls within a range of datesprior to the pre-determined maintenance.

If at 516 the initial determined date or range of dates falls within therange of dates prior to the pre-determined maintenance, at 518, thecontroller of the coating restoration system cancels the date or rangeof dates determined and removes the engine or aircraft (in such anembodiment) from a restoration schedule. If at 516, the initialdetermined date or range of dates does not fall within the range ofdates prior to the pre-determined maintenance, at 520 the controller ofthe coating restoration system leaves the determined date on therestoration schedule.

At 522, in an embodiment where the engine is on an aircraft and thataircraft belongs to a fleet of aircraft, the updated restorationschedule is communicated to a fleet operation controller. At 524, thefleet operation controller determines the percentage of aircraft in thefleet that are on the restoration schedule for the date or range ofdates from maintenance.

At 526, if the percentage of aircraft in the fleet that are on therestoration schedule for the date exceeds a threshold percentage, thefleet operation controller will delay the restoration for apredetermined amount of time when the percentage falls below thethreshold percentage. At 528, if the percentage of aircraft in fleetthat are on the restoration schedule for the date does not exceed athreshold percentage the fleet operation controller leaves thedetermined date or range of dates on the restoration schedule.

FIG. 4 shows a flow chart of a method of restoring a coating 600. At 602the measurements of parameters of a turbine engine are taken in a testcell prior to use of the turbine engine. At 604 an engine profile isformed based the measurements or historical data of similar engines andinputted or communicated to the controllers of a control system.

At 606, a controller monitors parameters of the engine during operation.These parameters can include engine temperature, different airtemperatures at the engine, fuel consumption and the like. At 608, in anembodiment where the engine is on an aircraft, parameters of theaircraft are inputted and communicated to controllers in the controlsystem. These parameters include environmental conditions during flight,flight durations, air speeds and the like.

At 610, a controller makes determinations based on the parameters of theengine and the aircraft. Based on these determinations the controlsystem determines a date or a range of dates for maintenance of theengine to restore a coating at 612.

At 614, on the date of restoration the controller of a coatingrestoration system determines based on the date of restoration and thedeterminations based on engine and aircraft parameters the surfaces ofthe engine to be coated, the amount of coating to be supplied and/or theconsistency of the coating materials.

As an example of how the methods of FIGS. 3 and 4 operate, when aturbine engine is manufactured for an aircraft, before securing theengine on the wing, test cell measurements are taken of the engine andinputted into the either the engine coating controller, enginemonitoring controller or both. This information is then communicatedwirelessly to all of the controllers in the control system. Duringoperation of the engine, the engine is utilized for the first time onJanuary 1^(st). The engine monitoring controller receives inputs fromthe aircraft engine controller regarding flight information, includingbut not limited to environmental conditions including temperature andprecipitation at take-off and landing, date and time of flight, airtemperature changes, relative humidity, air quality, air speed and windconditions for each flight during operation. Simultaneously, the enginemonitoring controller receives inputs from engine sensors regarding theair temperature of the exhaust in the engine and fuel consumed. Theinformation and data inputted and received is stored in the memory ofthe engine monitoring controller and communicated to the enginecontroller during all operations of the engine. The controllers utilizealgorithms to determine the profile of the engine after completion ofeach flight based on the information and data gathered during operationand based on historical data.

In the example, after a flight on June 1^(st) of the same year, thecalculated profile based on engine exhaust temperature is compared tothe engine profile formed during testing, and a controller determinesmaintenance is not needed. The algorithm then determines based on thehistorical data of the engine parameters to that date, at the currentpace of wear the thermal barrier coating of the engine should berestored on September 1 of the same year. This information iscommunicated to all of the controllers in the control system includingthe one or more controllers of the coating restoration system and theone or more fleet operation controllers. The one or more controllers ofthe coating restoration system then compare the September 1 date to theregularly scheduled maintenance date of the engine, which is January 1of the next year. Because the September 1 date is more than one monthaway, the one or more controllers of the coating restoration systemschedule the engine for maintenance on September 1 of this year. Theinformation is then communicated to the other controllers of the controlsystem including the one or more fleet operations controllers.

In the example, the one or more fleet operations controllers receive theinformation that the engine is scheduled for restoration of the thermalbarrier coating on September 1 of this year. The fleet operationscontroller then calculates the percentage of aircraft in the fleet thatare currently scheduled for maintenance on September 1 is 2% or lessthan the 3% threshold percentage of aircraft in the fleet undergoingmaintenance for that day. As a result, the fleet operations controllerdoes not change the date of the scheduled maintenance and the engine isscheduled for maintenance on September 1. On the day of maintenance, theone or more controllers of the coating restoration system have thecoating restoration system provide the pre-determined amount of coatingof the engine to restore the engine profile.

In a second example, the same steps occur as the first example, whereinafter the June 1^(st) flight a controller makes an initial determinationthat the maintenance is to occur on September 1 of this year. This timethe engine profile is determined as a result of monitoring the thermalbarrier coating using methods outlined in U.S. Pat. No. 9,395,301. Againthe one or more controllers of the restoration system determines thatregularly scheduled maintenance is not until January 1 of next year andleaves the aircraft on the restoration schedule for maintenance forSeptember 1 of this year and communicates this information to the fleetoperations controller. In this second example, the fleet operationscontroller calculates the percentage of aircraft scheduled formaintenance is 4%, above the threshold percentage of aircraft. The fleetoperations controller then determines the maintenance date to be October1 of this year when only 2% of aircraft are scheduled for maintenance.The new maintenance date is then communicated to the other controllersin the control system including the one or more controllers of thecoating restoration system that again compares date to the regularlyscheduled maintenance and because it is more than a month away, keepsthe October 1 maintenance date scheduled.

In the second example, when the October 1 maintenance occurs, the one ormore controllers of the coating restoration system restores the thermalbarrier coating by increasing the amount of coating and surface area ofthe engine the spray device covers compared to the amount of coating andsurface area coated if the maintenance occurred on September 1 as wasoriginally scheduled. In this manner, the coating restoration systemcompensates for the late maintenance by enhancing the restoration.

In a third example, the same steps occur as the first example with theengine profile being determined based on engine efficiency. In thisthird example, after the June 1^(st) flight a controller makes aninitial determination that the maintenance is to occur in a range ofdates between December 7-14 of this year. These initial dates ofmaintenance are scheduled and communicated to the other controllersincluding the one or more controllers of the coating restoration system.The one or more controllers of the coating restoration system thencompares the scheduled range of dates to the regularly scheduledmaintenance of the engine on January 1 of the next year and determinesthis is within one month of the regularly scheduled maintenance. Thus,the one or more controllers of the coating restoration system moves themaintenance of the thermal barrier coating to the date of the regularlyscheduled maintenance, cancelling the December 7-14 maintenance.

In the third example, at the regularly scheduled maintenance, similar tothe second example, the amount of coating and surface area of the enginethe spray device covers increases based on the later maintenance datescheduled compared to the original date calculated by engine monitoringcontroller. Thus, additional protection is provided.

In a fourth example, the same steps occur as the first example, onlyafter the June 1^(st) flight the algorithm makes an initialdetermination that the maintenance is not to occur until February 1 ofthe next year. This initial date of maintenance is scheduled andcommunicated to the other controllers including the one or morecontrollers of the coating restoration system. The one or morecontrollers of the coating restoration system then compares thescheduled date to the regularly scheduled maintenance of the engine onJanuary 1 of the next year and determines this is after the regularlyscheduled maintenance. Thus, the one or more controllers of the coatingrestoration system moves the maintenance of the thermal barrier coatingto the date of the regularly scheduled maintenance, cancelling theFebruary 1 maintenance.

In the fourth example, at the regularly scheduled maintenance, theamount of coating and surface area of the engine the spray device coversdecreases compared to the amount and surface area if maintenance wouldhave occurred on February 1. Thus, based on the earlier maintenance datescheduled compared to the original date calculated by engine monitoringcontroller not as much restoration is required and the restorationapplication is altered.

In an additional example the engine monitoring controller monitors theamount of engine cycles and the average ambient temperature of the planeduring operation. Based on these parameters the control system utilizesa look up table to determine a maintenance date for the engine.

In another example the engine monitoring controller or the enginecoating controller monitors historical data or real time data of engineand airplane parameters. Such parameters include one or more of anengine exhaust temperature, a condition of the coating of the engine,engine fuel flow, compressor exit pressure, compressor exit temperature,engine derating, engine speed, engine cycles, engine power use,environmental conditions, ambient airplane temperature or dates ofengine use. Based on one or more of these parameters, the control systemdetermines a maintenance date for the engine. The system on themaintenance date applies an additive to increase the useful life of theengine to greater than 100%. For example, if an initial coating on or inan engine has a useful life of 1,000 engine cycles but, after some useof the engine the coating has a remaining useful life of 750 enginecycles, application of the additive to the coating may increase theuseful life of the coating to 1,100 total engine cycles or may increasethe useful life by an additional 300 engine cycles such that the actualtotal useful life of the coating is extended beyond the initial 100%.

As another example, the determination of when to extend a useful life ofa coating in or on an engine may not be based on a static or absolutedate, but may be a relative time. For example, due to different enginesbeing used different amounts, identical coatings on different enginesmay need restoration or application of additives at different times. Theone or more controllers described herein may direct application of theadditive to a coating as a number of engine cycles. The additive mayneed to be applied before expiration or upon expiration of the number ofengine cycles. Optionally, one or more controllers described herein maydirect application of the additive to a coating as a trigger point. Thetrigger point can be a point in time at which the additive should beapplied to the coating before continued use of the engine after thetrigger point occurs. A trigger point can be a number of engine cycles,a number of hours of engine usage, or the like.

In one embodiment, a control system is provided. The control system hasone or more controllers configured to determine when to extend a lifespan of a coating of an engine by applying an additive to the coatingbased on one or more monitored parameters of the engine. The one or morecontrollers also are configured to, direct application of the additiveonto a coating of the engine based on the monitored parameters of theengine.

In one embodiment, the coating is a thermal barrier coating.

In one embodiment, the one or more controllers include an engine coatingcontroller and a fleet operation controller. The engine coatingcontroller is configured to determine an initial maintenance date andthe fleet operation controller is configured to determine themaintenance date. In one embodiment, the determined maintenance date islater than the initial maintenance date. In this embodiment, the one aremore controllers are configured to increase the amount of coatingsprayed on the engine based on the maintenance date determined by thefleet operation controller.

In one embodiment, the one or more controllers include an engine coatingcontroller and a controller of a restorative coating system. The enginecoating controller determines an initial maintenance date based on themonitored parameters of the engine and the controller of the restorativecoating system is configured to determine the maintenance date. In oneembodiment, the determined maintenance date is later than the initialmaintenance date. In this embodiment, the one are more controllers areconfigured to increase the amount of coating sprayed on the engine basedon the maintenance date determined by the controller of the restorativecoating system.

In one embodiment, the monitored parameter of the engine includes one ormore of an engine exhaust temperature, a condition of the coating of theengine, engine fuel flow, compressor exit pressure, compressor exittemperature, engine derating, engine speed, engine cycles, engine poweruse, environmental conditions, ambient airplane temperature or dates ofengine use.

In one embodiment, the one or more controllers are configured todetermine an amount of additive to apply onto the coating based on themonitored parameters. In another embodiment, the one or more controllersare configured to determine the type of additive to apply onto thecoating based on the monitored parameters.

In one embodiment, a method of coating an engine is provided. Stepsinclude monitoring engine parameters with one or more controllers anddetermining an engine maintenance date with the one or more controllersbased on the monitored engine parameters. A coating restoration systemhaving a mobile spray device is provided and coats the engine with thespray device on the engine maintenance date based on the monitoredengine parameters.

In one embodiment, the method additionally provides the step ofdetermining the engine maintenance date comprises the steps of testingthe engine to form an engine profile and comparing the monitored engineparameters to the formed engine profile to determine an initial enginemaintenance date. The initial maintenance date is communicated to afleet operation controller and the percentage of aircraft in a fleetundergoing maintenance on the engine maintenance date is determined. Theengine maintenance date is then determined based of the percentage ofaircraft in a fleet undergoing maintenance on the engine maintenancedate. In one embodiment, when the percentage of aircraft is above athreshold percentage the determined engine maintenance date is differentthan the initial engine maintenance date.

In one embodiment, the step of determining the engine maintenance datecomprises the steps of testing the engine to form an engine profile andcomparing the monitored engine parameters to the formed engine profileto determine an initial engine maintenance date. The initial maintenancedate is communicated to a controller of a restorative coating system.Then the initial engine maintenance date is compared to a regularlyscheduled maintenance date and the maintenance date is determined basedon the regularly scheduled maintenance date. In one embodiment, thedetermined engine maintenance date is different than the initial enginemaintenance date. In this embodiment, the controller of the restorativecoating system can increase an amount of coating based on the enginemaintenance date being different than the initial engine maintenancedate. In this embodiment, the controller of the restorative coatingsystem can change a spray pattern of the spray device based on theengine maintenance date being different than the initial enginemaintenance date. In this embodiment, the controller of the restorativecoating system can change the consistency of spray based on the enginemaintenance date being different than the initial engine maintenancedate.

In one embodiment, a control system is provided with one or morecontrollers configured to monitor one or more parameters of an engine.The one or more controllers also are configured to determine an additiveapplication to direct on the engine based on the one or more monitoredparameters of the engine. The additive application in one embodimentextends the life of the engine to greater than 25% of a measured initiallife span of the engine. In another embodiment, the one or morecontrollers also are configured to determine when the additiveapplication is directed on the engine.

Also provided herein is a coating system utilized to coat a componentwith an atomizing spray device. The coating system may be used to applythe additives to the thermal barrier coatings, as described above. Thecoating restoration system optionally includes a 360-degree rail andglider, where the glider has an attachment tool to methodically move theglider to locate the glider anywhere in relation to a component, such asa turbine. In this manner, an atomizing spray device attached to theglider applies a coating (e.g., a coating of an additive) on allsurfaces of the component (or on a thermal barrier coating of thecomponent) and at any given angle without the need of removing thecomponent from existing machinery or disassembling the component. Theprocess includes the selecting the nozzle spray angle, the spray rates,the spray duration, the glider travel speeds during spraying, the numberof passes over the targeted liner surface, and/or the suitability of aliner for coating based on the condition of the thermal barrier coating.

The various spray devices disclosed herein can apply the additive to athermal barrier coating from significantly larger working or standoffdistances than other known spray devices. For example, some known spraydevices may require being located within a centimeter or less from thesurface receiving the additive. In contrast, the shapes of the outletsand/or interior chambers of the spray devices described herein are ableto atomize and spray the additive while being located farther from thesurfaces receiving the additive. For example, the spray devices may havea standoff distance of (e.g., be located from the surface being sprayed)two to forty centimeters.

According to the method of coating the component, two fluid streams(typically one liquid and one gas) are introduced into a device throughfluid inlets of the device to combine at fluid outlets and to formdroplets that comprise a slurry of ceramic particles in a gas. Thesestreams may be combined into the droplets by mixing the fluid streamsoutside of an outer housing of the atomizing spray device. Optionally,one or more embodiments of the atomizing spray device may mix the fluidstreams inside the outer housing of the atomizing spray device. Thedroplets formed outside or inside the atomizing spray device aretwo-phase droplets of ceramic particles within the fluid. In particular,the first fluid stream is a slurry that includes a first fluid such asan alcohol or water and the ceramic particle that is to be deposited onthe component as at least one of the additives described above. Thesecond fluid is typically a gas such as air, nitrogen or argon thatmixes with the slurry and forms the shape of the spray resulting fromthe plurality of droplets formed from the slurry and gas discharged fromthe spray device.

The first fluid is selected to promote evaporation of the fluid as thetwo-phase droplets traverse through the air before the droplets impactthe surface of a component. A fluid is selected to promote evaporationwhen the kinetic energy required to transform a given volume of thefluid from liquid to gas is less than the kinetic energy required totransform the same volume of water into water vapor. Additionally,evaporation is promoted by increasing the amount of evaporation comparedto if that step was not taken. Thus, promoting evaporation can encompasspartial evaporation of a fluid, complete evaporation of a fluid, or whenpartial evaporation of a fluid occurs during a time when the fluid istraversing through the air and finishes complete evaporation uponcontacting a surface. Similarly, the temperature of the first fluid isselected or increased to again promote evaporation of the fluid afterthe fluid is discharged from the spray device but before impacting acomponent. Thus, either the first fluid is eliminated from the coatingbecause of complete evaporation of the fluid prior to droplet impact orthe amount of fluid impacting the component is substantially reduced.The amount of fluid remaining in the droplet impacting the component isconsidered substantially reduced when more than 50% of the fluid byweight of the fluid discharged by the spray device evaporates beforeimpacting the component. By eliminating or minimizing fluid in thedroplets a dry coating is provided that improves adhesion, fineatomization and uniformity of the coating layer. This also eliminates orminimizes cracking and imperfections within the coating after theapplication of the coating. Such imperfections occur because of theevaporation of the first fluid within the coating after application andbubbling cause by the fluids. The end result is a coating that is bothuniform and less susceptible to wear and degradation during the life ofthe coating.

The atomizing spray devices disclosed herein are examples of spraydevices that are utilized to accomplish the method of applying anadditive to a coating of a component. Each individual spray device hasadvantages and results in different distributions of spray and coatingsto occur at the surface of the component. Thus, a user of the coatingrestoration system may select the spray device depending on thecomponent and the desired coating an end user desires. Additional spraydevices can be provided that have elements or features of the disclosedspray devices, are a combination of the spray devices disclosed orprovide components and elements not described as part of the disclosedspray devices yet still function to apply a coating to a componentutilizing the method taught herein.

In some embodiments of the atomizing spray device, a device referred toas a pintle is utilized. A pintle generally is one or more targetsurfaces or areas utilized to atomize a gas, fluid and/or slurry movingpast the surfaces. The pintle has a converging shape that narrows,tapers, is conical or otherwise reducing in size.

FIG. 5 is a schematic diagram of one embodiment of a coating system 700.The coating system 700 may be used as a coating restoration system thatrestores (e.g., repairs, replenishes, augments, etc.) an existing orpreviously applied coating on a surface, or may be used to initiallyapply or otherwise deposit a coating onto the surface. The system 700includes a rail element 702 and glider element 704 that function toallow 360 degrees of movement in comparison to a component 706 thatneeds to be restored or coated. The rail element 702 is an elongatedbody on which the glider element 704 moves along to coat or restore acoating on different locations of the component 706. The rail element702 may be placed inside the component 706 to allow the coating to beapplied onto interior surfaces of the component 706. The component 706can be any mechanical component including but not limited to acombustor, a turbine, a nozzle, a blade or the like. The component 706can also be part of any machinery including, but not limited to acommercial airliner or the like. In one example, the engine 102 isrepresented by the component 706 in FIG. 5.

An attachment 708 is provided on the glider element 704 to receive aspray device 710, that in one embodiment is an atomizing spray device,to provide the coating (or apply the additive) to the component 706. Inone embodiment, the coating or additive is utilized to restore a thermalbarrier coating of the component 706. The spray device 710 receivesfluid from one or more reservoirs 712, 714 via one or more pumps (notshown) to provide a slurry that includes the fluid and ceramic particlesinto the spray device 710 that is atomized and discharged by the spraydevice 710 to form droplets that impact the component 706 to form thecoating. The fluid can be water and the ceramic particles can be anysolid particles that function to form a coating or that deliver anadditive to the component 706. The droplets may be formed outside of theouter housing or outer surfaces of the device such that the fluid andceramic particles do not mix until the fluid and ceramic particles areoutside of the device.

In one embodiment, a first or fluid reservoir 712 contains a fluid suchas water, alcohol, or the like. The fluid of the first reservoir can beselected to promote evaporation of the fluid in the droplet formed bythe spray device 710 as the droplet traverses through the air from thespray device 710 before impacting the component 706. In this manner, thefluid is either eliminated from the droplet that impacts the component706 or the amount of fluid remaining in the droplet impacting thecomponent 706 is substantially reduced. The fluid may be a liquid in oneor more embodiments, but alternatively may include a gas.

Similarly, the temperature of the fluid in the system 700 can beincreased, either by a heating element 716, or other device or methodsuch that when the fluid is finally discharged from the spray device 710again the amount of fluid remaining in the droplet impacting thecomponent 706 is substantially reduced. Such increase in temperature, orheating, can occur at the fluid reservoir 712, in conduits conveying thefluid to the spray device 710 or within the spray device 710. In oneexample, both the temperature of the fluid is increased within thesystem and the fluid is selected to promote evaporation.

The fluid reservoir 712 is also designed to reduce the amount of gasfrom evaporated fluid that is conveyed to the spray device 710 relativeto one or more other reservoirs. Specifically, the fluid reservoir canhave an outlet adjacent the bottom of the reservoir or can be cooled toprevent gas from evaporated fluid from flowing from the reservoir 712.This ensures that the slurry of fluid and ceramic particles can becreated and ensures a minimal amount of fluid evaporates in the systemprior to discharging the fluid as part of the slurry from the spraydevice 710.

In an embodiment, a second or gas reservoir 114 is also provided. Thereservoir contains a fluid that typically is a gas and thus isconsidered a gas reservoir. The gas in the gas reservoir 114 can includeair, nitrogen, argon and the like. The gas flows from the gas reservoir114 to the spray device 110 so the gas can be combined with the slurryby the spray device 110 to form the droplets that coat the component106.

Each of the groups of FIGS. 6-8, 9-11, 12-14, 15-17, and 18-20 shows anexample of an atomizing spray device 710. Other examples and embodimentsof the atomizing spray devices 710 can be provided without fallingoutside of this disclosure. FIGS. 7-6-8 show a first atomizing spraydevice 810 that can be utilized within a coating restoration system. Thespray device 810 has an outer housing 812 having a hollow chamber 814disposed therethrough. The hollow chamber 814 extends through thehousing 812 from a chamber inlet 816 through a first chamber section 817that has a first diameter and narrows to a second chamber section 818that has a diameter that is less than the diameter of the first chambersection 817. The narrowing diameter causes fluid therein to increase inspeed through the second chamber section 818.

The second chamber section 818 extends into a third chamber section 820that arcuately extends from the second chamber section 818 toward anouter wall of the housing 812. The third chamber section 818 has anouter diameter 822 that curves outwardly and then inwardly toward acenter axis 823 of the hollow chamber 814. This shape provides a conicalshaped section that converges toward and terminates in an annular outlet824. The curvature of the outer diameter 822 of the third chambersection 818 determines the angle at which fluid flowing through thehollow chamber exits the annular outlet 824 and toward a center axis 823of the hollow chamber 814.

A conduit 826 is disposed through the hollow chamber 814 and iscentrally located within the hollow chamber 814 along the center axis823 of the hollow chamber 814. The conduit 826 extends through thehollow chamber 814 from a conduit inlet 828 through a first conduitsection 830 that has a first diameter and narrows to a second conduitsection 832 that has a diameter that is less than the diameter of thefirst conduit section 830 to cause fluid therein to increase in speedthrough the second conduit section 832. Rib elements 834 are disposedwithin the hollow chamber 814 and engage the conduit 826 to support theconduit 826 within the hollow chamber 814 while allowing fluid flowthrough the hollow chamber 814. The second conduit section 832 extendsarcuately through the third chamber section 818 toward the outer wall ofthe housing to a conduit outlet 836 continuing to extend along thecenter axis 823 of the chamber 814. The conduit outlet 836 is centrallylocated within the annular outlet 824 of the hollow chamber 814 suchthat the fluid flowing from the annular outlet 824 is angled toward thefluid flowing through the conduit outlet 836 to control the diameter ofthe resulting spray flowing through the conduit outlet 836.

During operation of the spray device 810 of this embodiment, a firstfluid such as air, nitrogen, argon or the like is pumped into thechamber inlet 816 by a pump (not shown) while a second fluid, such asalcohol or water, contains ceramic particles therein to form a slurryand is pumped by a pump (not shown) through the conduit 826. The firstfluid flows through the sections of the hollow chamber 814 and is angledby the curve of the outer diameter of the third chamber section 818 toform an air jet directed toward the slurry that flows through theconduit outlet 836. When discharged the first fluid and slurry combineto form two-phase droplets. As the droplets traverse toward the surfaceof the component the second fluid evaporates leaving only the ceramicparticles to provide a uniform coating of the surface of the component.The resulting spray on the surface of the component is a circular sprayhaving a Gaussian distribution at the surface of the component.

FIGS. 9-11 show another embodiment of an atomizing spray device 910 thatcan be utilized within a coating restoration system. The spray device910 has an outer housing 912 having a hollow chamber 914 disposedtherethrough. The hollow chamber 914 extends through the housing 912from a chamber inlet 916 through a first chamber section 917 that has afirst diameter and narrows to a second chamber section 918 that has adiameter that is less than the diameter of the first chamber section. Asdescribed above, these different diameters cause fluid therein toincrease in speed through the second chamber section 918.

The second chamber section 918 extends into a third chamber section 920that arcuately extends from the second chamber section 918 toward anouter wall of the housing 912. The third chamber section 918 has anouter diameter 922 that curves outwardly away from a center axis 923 ofthe chamber 914 to provide a conical shaped section that terminates inan annular outlet 924. The curvature of the outer diameter 922 of thethird chamber section 918 determines the angle at which fluid flowingthrough the hollow chamber 914 exits the annular outlet 924 and awayfrom a center axis 923 of the chamber 914.

A conduit 926 is disposed through the hollow chamber 914 and iscentrally located within the hollow chamber 914. The conduit 926 extendsthrough the hollow chamber 914 from a second or conduit inlet 928through a first conduit section 930 that has a first diameter andnarrows to a second conduit section 932 that has a diameter that is lessthan the diameter of the first conduit section 930 to cause fluidtherein to increase in speed through the second conduit section 932. Ribelements 934 are disposed within the hollow chamber 914 and engage theconduit 926 to support the conduit 926 within the hollow chamber 914while allowing fluid flow through the hollow chamber 914. The secondconduit section 932 extends arcuately through the third chamber section918 toward the outer wall of the housing to a conduit outlet 936. Inthis embodiment, at the conduit outlet 936 the second conduit sectionincreases in diameter and extends away from the center axis of thechamber 914 to form a conically shaped outlet 936.

In this embodiment, a pintle 938 is disposed within the outlet 936 andengages the second conduit section 932 within the outlet 936 against asidewall of the outlet 936 that is extending away from the center axisof the chamber 914. The pintle is secured such that a center axis 939 ofthe pintle 938 is off set from the center axis 923 of the chamber 914 atthe outlet 924. The pintle 938 is conically shaped extending from asmaller diameter first end 940 to a larger diameter second end 942 thathas an edge 943 and causes atomization of the slurry off the edge 943 ofthe larger diameter second end 942.

During operation of the spray device 910 of this embodiment, a firstfluid such as air, nitrogen, argon or the like is pumped into thechamber inlet 916 by a pump (not shown) while a second fluid, such asalcohol or water, contains ceramic particles therein to form a slurrythat is pumped by a pump (not shown) through the conduit 926. The firstfluid flows through the sections of the hollow chamber 914 and is angledaway from the center axis 923 of the chamber 914. The first fluid or gasflows past the edge 943 of the pintle 938 to atomize the fluid.Meanwhile, the slurry flows through the conduit outlet 936 also awayfrom the center axis 923 of the chamber 914 and past the edge 943 of thepintle 938 to atomize the slurry. As a result, when gas and slurry aredischarged from the spray device they mix to form two-phase droplets.The first fluid also acts to direct the droplets to form a conicallyshaped spray thus causing a circular spray pattern with a hollowinterior, or a ring shape, at the surface of a component. As thedroplets traverse toward the surface of the component, the second fluidwithin the droplets evaporates leaving only the ceramic particles toprovide a uniform, liquid free coat at the surface of the component.

FIGS. 12-14 show yet another embodiment of an atomizing spray device1010 that can be utilized within a coating restoration system. The spraydevice 1010 has a housing 1012 having a hollow chamber 1014 disposedtherethrough. The hollow chamber 1014 extends through the housing 1012from a chamber inlet 1016 through a first chamber section 1017 that hasa first diameter and narrows to a second chamber section 1018 that has adiameter that is less than the diameter of the first chamber section tocause fluid therein to increase in speed through the second chambersection 1018. The second chamber section 1018 extends into a thirdchamber section 1020 that arcuately extends from the second chamber 1018toward an outer wall of the housing 1012. The third chamber section 1018has an outer diameter 1022 that curves outwardly away from a center axis1023 of the chamber 1014 to provide a conical shaped section thatterminates in an annular outlet 1024. The curvature of the outerdiameter 1022 of the third chamber section 1018 determines the angle atwhich fluid flowing through the hollow chamber exits the annular outlet1024 and away from the center axis 1023 of the chamber 1014.

A conduit 1026 is disposed through the hollow chamber 1014 and iscentrally located within the hollow chamber 1014. The conduit 1026extends through the hollow chamber 1014 from a conduit inlet 1028through a first conduit section 1030 that has a first diameter andnarrows to a second conduit section 1032 that has a diameter that isless than the diameter of the first conduit section 1030 to cause fluidtherein to increase in speed through the second conduit section 1032.Rib elements 1034 are disposed within the hollow chamber 1014 and engagethe conduit 1026 to support the conduit 1026 within the hollow chamber1014 while allowing fluid flow through the hollow chamber 1014. Thesecond conduit section 1032 extends arcuately through the third chambersection 1018 toward the outer wall of the housing to a conduit outlet1036. In this embodiment, at the conduit outlet 1036 the second conduitsection increases in diameter and extends away from the center axis 1023of the third chamber 1014 to form a conically shaped outlet 1036.

In this embodiment, a pintle 1038 is provided similar to the embodimentof FIGS. 6-8. In this embodiment, the pintle 1038 again is disposedwithin and engages the second conduit section 1032. However, in thisembodiment, the pintle 1038 does not engage the outlet 1036. As aresult, the first end 1040 of the pintle 1038 having a smaller diameterextends along the center axis 1023 of the chamber 1014 adjacent theconduit outlet 1036 such that the center axis 1039 of the pintle 1038aligns with and is the same as the center axis 1023 of the hollowchamber 1014 at the outlet 1036. The pintle 1038 again is conicallyshaped extending from the smaller diameter first end 1040 to a largerdiameter second end 1042 with atomization of the slurry occurring at theedge 1043 of the larger diameter end 1042. The pintle 1038 extends toits second end 1042 in such a way to provide even spacing between thepintle 1038 to the conduit outlet 1036 around the entire conduit outlet1036. The pintle 1038 is this embodiment is fully within the housing1012 and allows for an annular slurry flow as a result of being alignedwith the center axis 1023 of the chamber 1014.

During operation of the spray device 1010 of this embodiment, a firstfluid such as air, nitrogen, argon or the like is pumped into thechamber inlet 1016 by a pump (not shown) while a second fluid, such asalcohol or water, contains ceramic particles therein to form a slurrythat is pumped by a pump (not shown) through the conduit 1026. The firstfluid flows through the sections of the hollow chamber 1014 and isangled away from the center axis 1023 of the hollow chamber 1014. Theslurry through the conduit outlet 1036 also away from the center axis1023 of the hollow chamber 1014 and around the pintle 1038. As a result,when the first fluid and slurry are discharged from the spray device1010 they mix to form two-phase droplets. The first fluid directs thedroplets to provide a conically shaped spray of the droplet. Thus, acircular spray pattern with a hollow interior, or a ring shape, occursat the surface of a component. As the droplets traverse toward thesurface of a component the liquid in the droplets evaporate leaving onlythe ceramic particles to coat the surface of the component to provide auniform coating.

FIGS. 15-17 show yet another embodiment of an atomizing spray device1110 that can be utilized within a coating restoration system. The spraydevice 1110 has a housing 1112 having a hollow chamber 1114 disposedtherethrough. The hollow chamber 1114 extends through the housing 1112from a chamber inlet 1116 through a first chamber section 1117 that hasa first diameter and narrows to a second chamber section 1118 that has adiameter that is less than the diameter of the first chamber section tocause fluid therein to increase in speed through the second chambersection 1118. In this embodiment, the second chamber section 1118 ishelically shaped or curves about a center axis 1123 of the chamber 1114.The second chamber section 1118 extends in this manner into a thirdchamber section 1120 that arcuately extends from the second chamber 1118toward an outer wall of the housing 1112. The third chamber section 1118has an outer diameter 1122 that curves outwardly away from the centeraxis 1123 of the chamber 1114 to provide a conical shaped section thatterminates in an annular outlet 1124. The curvature of the outerdiameter 1122 of the third chamber section 1118 determines the angle atwhich fluid flowing through the hollow chamber exits the annular outlet1124 and away from the center axis 1123 of the chamber 1114.

A conduit 1126 is disposed through the hollow chamber 1114 and iscentrally located within the hollow chamber 1114. The conduit 1126extends through the hollow chamber 1114 from a conduit inlet 1128through a first conduit section 1130 that has a first diameter andnarrows to a second conduit section 1132 that has a diameter that isless than the diameter of the first conduit section 1130 to cause fluidtherein to increase in speed through the second conduit section 1132.Similar to the second chamber section 1118, the second conduit section1132 is helically shaped or curves about a center axis 1123 of thehollow chamber 1114. Rib elements 1134 are disposed within the hollowchamber 1114 and engage the conduit 1126 to support the conduit 1126within the hollow chamber 1114 while allowing fluid flow through thehollow chamber 1114. The second conduit section 1132 extends arcuatelythrough the third chamber section 1118 toward the outer wall of thehousing to a conduit outlet 1136. In this embodiment, at the conduitoutlet 1136 the second conduit section increases in diameter and extendsaway from the center axis 1123 of the chamber 1114 to form a conicallyshaped outlet 1136.

In this embodiment, a pintle 1138 is provided similar to the embodimentof FIGS. 9-11. In this embodiment, the pintle 1138 is disposed withinand engages the second conduit section 1132, but does not engage theoutlet 1136. As a result, the first end 1140 of the pintle 1138 having asmaller diameter extends along the center axis 1123 of the chamber 1118adjacent the conduit outlet 1136. In this manner, the center axis 1139of the pintle 1138 aligns or is the same as the center axis 1123 of thechamber 1114 at the outlet 1124. The pintle 1138 again is conicallyshaped extending from the smaller diameter first end 1140 to a largerdiameter second end 1142 with atomization of the slurry occurring at theedge 1143 of the larger diameter end 1142. The pintle 1138 extends toits second end 1142 in such a way to provide even spacing between thepintle 1138 to the conduit outlet 1136 around the entire conduit outlet1136. The pintle 1138 is this embodiment is fully within the housing1112 and allows for an annular slurry flow as a result of being alignedwith the center axis 1123 of the chamber 1114.

During operation of the spray device of this embodiment, a first fluidsuch as air, nitrogen, argon or the like is pumped into the chamberinlet 1116 by a pump (not shown) while a second fluid, such as alcoholor water, contains ceramic particles therein to form a slurry that ispumped by a pump (not shown) through the conduit 1126. In thisembodiment, the pressurization of the fluid should be increased toaddress loss in speed as a result of the helix shaped chamber 1114 andconduit 1126. As the first fluid flows through the second chambersection 1118 and flows through the helically shaped section to causeincrease sheer over the pintle 1138 thus providing a finer, moreefficient atomization and finer film of gas resulting passing the pintle1138. Similarly, as the slurry flows through the second conduit section1132 and through the helically shaped section, sheer at the pintle 1138is increased providing a finer, more efficient atomization and finerfilm of slurry passing the pintle 1138.

Similar to the embodiment of FIGS. 9-11, the first fluid at the thirdchamber section 1118 is angled away from the center axis 1123 of thechamber 1114. At this time, the slurry flows through the conduit outlet1136 also away from the center axis 1123 of the chamber 1114 and aroundthe pintle 1138. As a result, the first fluid and slurry mix after beingdischarged from the spray device 1110 to form two phase droplets thattraverse toward a component surface. The first fluid directs thedroplets to provide a conically shaped spray of the droplets causing acircular spray pattern with a hollow interior, or a ring shape, at thesurface of a component. As the droplets flow toward the surface of thecomponent, the liquid in the droplets evaporates leaving only theceramic particles to provide a uniform coat at the surface of thecomponent. The spray distributions at the surface of the component foreach of the embodiments shown in FIGS. 6-17 provide dual peaks, with apeak distribution at an outer perimeter and then a second peak at theinner perimeter of the coating.

FIGS. 18-20 show another example of an atomizing spray device 1210 thatcan be utilized within a coating restoration system. The spray device1210 has a housing 1212 having a hollow chamber 1214 disposedtherethrough. The hollow chamber 1214 extends through the housing 1212from a chamber inlet 1216 through a first chamber section 1217 that hasa first diameter and narrows to a second chamber section 1218 that has adiameter that is less than the diameter of the first chamber section tocause fluid therein to increase in speed through the second chambersection 1218. The second chamber section 1218 extends into a thirdchamber section 1220 that arcuately extends from the second chamber 1218toward an outer wall of the housing 1212. The third chamber section 1218has an outer diameter 1222 that curves inwardly toward a center axis1223 of the chamber 1214 and terminates at an outlet 1224 that has anangled surface 1225 to form an oval shape outlet 1224 in the outer wallof the housing 1212.

A conduit 1226 is disposed through the hollow chamber 1214 and iscentrally located within the hollow chamber 1214. The conduit 1226extends through the hollow chamber 1214 from a conduit inlet 1228through a first conduit section 1230 that has a first diameter andnarrows to a second conduit section 1232 that has a diameter that isless than the diameter of the first conduit section 1230 to cause fluidtherein to increase in speed through the second conduit section 1232.Rib elements 1234 are disposed within the hollow chamber 1214 and engagethe conduit 1226 to support the conduit 1226 within the hollow chamber1214 while allowing fluid flow through the hollow chamber. The secondconduit section 1232 extends arcuately through the third chamber section1218 toward the outer wall of the housing to a conduit outlet 1236. Theconduit outlet 1236 has an angled surface 1237 similar to the chamberoutlet 1224 such that the oval shape of the chamber outlet surrounds theoval shape of the conduit outlet 1236. Therefore, fluid flowing from theoutlet 1224 is angled toward the slurry flowing through the conduitoutlet 1236 to control the perimeter of the resulting spray flowingthrough the conduit outlet 1236.

During operation of the spray device 1210 of this embodiment, a firstfluid such as air, nitrogen, argon or the like is pumped into thechamber inlet 1216 by a pump (not shown) while a second fluid, such asalcohol or water, contains ceramic particles therein to form a slurrythat is pumped by a pump (not shown) through the conduit 1226. The firstfluid flows through the sections of the hollow chamber 1214 and isangled by the third chamber section 1218 toward the slurry that flowsthrough the conduit outlet 1236. When the first fluid and slurry aredischarged from the spray device 1210 they mix to form two-phasedroplets. As a result of the angled shape of the chamber outlet 1224 andthe angled shape of the conduit outlet 1236, the first fluid directs thedroplets to provide an oval-shaped spray of the second fluid causing asolid oval-shaped spray pattern at the surface of a component. As thedroplets flow toward the surface of a component the liquid in thedroplets evaporates leaving only the ceramic particles to provide auniform coat at the surface of the component. The spray device 1210 ofthis embodiment is referred to as a fan nozzle design and the spraydevice provides a flat spray (as compared to the conical sprays of FIGS.6-17) that widens the spray area that is coated. Distribution of thespray at the surface has an extended central peak.

FIG. 21 illustrates a flow chart of one embodiment of a method 1300 forcoating a component with a spray device. According to the method ofcoating a component, at 1302, a coating application where a componentneeds to be coated is determined to be presented. An atomizing spraydevice is provided at 1304. At 1306, a fluid for mixing with ceramicparticles to form a slurry is selected to promote evaporation of thefluid during the spraying process. At 1308, the temperature of the fluidflowing through the spray device outlet is selected to promoteevaporation of the fluid during the spraying process. At 1310, theatomizing spray device forms two-phase droplets. The two-phase dropletsof ceramic particles then traverse through the air toward the surface ofthe component at 1312. At 1314, while the two-phase droplets are in theair before impacting the surface of the component the selected fluidevaporates from the two-phase droplets. The droplets then coat thesurface of the component at 1316.

In a first example of the method, a turbine engine on the wing of anairplane has a thermal barrier coating that is to be restored. Afterselecting the atomizing spray device, alcohol is chosen as the fluid tobe mixed with the ceramic particles to form the slurry, because alcoholis a fluid that promotes evaporation. In this example, the temperatureof the fluid is not selected or increased to promote evaporation of thespray. After the spray device discharges the fluid as part of a slurryfrom the spray device, a droplet that includes the fluid is formed. Asthis droplet traverses through the air, the fluid evaporatessubstantially reducing the amount of fluid in the droplet before thedroplet impacts the surface of the turbine to form the thermal barriercoating.

In a second example of the method when a fan blade requires a coatingthe atomizing spray device is chosen. Water is the fluid selected to bemixed with the ceramic particles to form the slurry and does not promoteevaporation of the fluid. In this example the temperature of thetwo-phase droplets is increased compared the temperature of thetwo-phase droplets without auxiliary heating of the droplets. Auxiliaryheating of the droplets can include, but is not limited to increasingthe temperature of the water flowing to the inlet of the spray device orincreasing the temperature of the water within the spray device as aresult of an additional heat source within the spray device, or thelike. By increasing the temperature of the fluid, in this example water,above the ambient temperature, kinetic energy is increased in thedroplets and the likelihood of evaporation of the water in the dropletsis more likely. Thus, the selected temperature of the fluid promotesevaporation. In this embodiment, the amount of water that evaporatesfrom the droplets substantially reduces the amount of water in thedroplet upon impact compared to the amount of water discharged from thespray device.

In an additional example, again, when a turbine engine is to be restoredthe fluid selected for mixing with the ceramic particles is alcohol topromote evaporation. In this embodiment, the ambient temperature is 20°C. (68° F.) and the selected temperature requires the temperature of thefluid entering the spray device to be increased to 40° C. (104° F.) topromote evaporation of the alcohol once the droplets are sprayed. Inthis embodiment, because of the selection of the alcohol and theincrease in the droplet temperature, again a substantial amount of thealcohol discharged from the spray device evaporates prior to thedroplets impacting the surface of the turbine engine.

In yet another example, a turbine engine is to be restored and the fluidselected for mixing with the ceramic particles is alcohol to promoteevaporation. In this embodiment, the ambient temperature again is 20° C.(68° F.). In this example, the selected temperature is in a rangebetween 25° C. (77° F.) and 78° C. (173° F.) or in a range below theboiling point of the alcohol to prevent evaporation within the spraydevice. After the discharge of the slurry and gas from the spray deviceand after the forming of the droplets, all of the alcohol in thedroplets evaporates such that when the droplets impact the turbineengine no alcohol remains as part of the coating.

In one embodiment, a system is provided. The system has a fluidreservoir containing a fluid that promotes evaporation when the fluid isexposed to gas and a spray device having one or more hollow chambershaving one or more conduits disposed therethrough that are fluidlyconnected to the first reservoir to receive a slurry containing thefluid and a mix of ceramic particles and the gas. Said one or moreconduits extend from a conduit inlet to a conduit outlet where theslurry is discharged to form droplets containing the fluid such that,based on a discharged amount of fluid in the droplets, the fluidpromotes evaporation when the fluid is exposed to a gas, as the dropletstraverse from the spray device toward an article. In one embodiment, thefluid contained in the droplets at least partially evaporates prior toimpacting the surface of the article being coated. In one embodiment a asecondary coating is discharged from the conduit outlet to provide atleast one of, removal of loose particles from the article, removal ofoverspray from cooling holes, or coating thickness control.

In one embodiment, a method is contemplated to provide a coating to acomponent. That method includes providing a spray device and supplying aslurry of a fluid and ceramic particles to the spray device. The slurryis then discharged from the spray device to form droplets containing thefluid to impact the component. As the droplets traverse from the spraydevice towards the component the fluid contained in the dropletsevaporates prior to impacting the component.

In one embodiment of the method the fluid is selected to promoteevaporation of the fluid prior to impacting the component. In thisembodiment, the fluid can be alcohol. In this embodiment, the fluid canalso be a fluid that has a lower boiling point than water provided atthe same atmospheric pressure as the fluid.

In another embodiment, the temperature of the slurry is increased topromote evaporation of the fluid prior to impacting the component. Inthis embodiment, the temperature of the slurry can be increased by atleast 10° C. to promote evaporation of the fluid prior to impacting thecomponent.

In one embodiment, all of the fluid contained in the droplets formedevaporate such that when the droplets impact the component the fluid iseliminated from the droplets. In another embodiment, more than 50% ofthe fluid by weight of the fluid discharged by the spray deviceevaporates prior to impacting the component.

In one embodiment, the method further comprises supplying a gas to thespray device and discharging the gas from the spray device. The gas isdirected toward the slurry discharged from the spray device to mix withthe slurry to form the droplets.

In one embodiment, the gas is selected from a group consisting of air,nitrogen, and argon. In an embodiment, the method further comprisesselecting the gas to promote the evaporation of the fluid in thedroplets prior to impacting the component.

In one embodiment, the droplets that impact the component form a thermalbarrier coating on the component. In another embodiment, the componentis a gas turbine.

In one embodiment the spray device comprises a housing and a hollowchamber disposed through the housing from a chamber inlet to a chamberoutlet. The hollow chamber has a conical shape adjacent the chamberoutlet that tapers inwardly toward a center axis of the hollow chamberand toward the chamber outlet such that a gas flowing through the hollowchamber is directed toward the center axis of the hollow chamber uponbeing discharged from the chamber outlet.

In this embodiment, the spray device further comprises a conduitdisposed through and centrally located within the hollow chamber from aconduit inlet to a conduit outlet and receiving the slurry. Inparticular, the slurry is discharged at the conduit outlet along thecenter axis of the hollow chamber such that the gas flowing through thechamber outlet that is directed toward the center axis of the hollowchamber combines with the slurry to form the droplets. The gas shapes aplurality of the droplets as the droplets are formed to provide auniform distribution of droplets on the component. In addition, acurvature of an outer wall of the hollow chamber that forms the conicalshape determines the angle at which the gas discharges from the chamberoutlet.

In one embodiment, the spray device comprises a housing and a hollowchamber disposed through the housing from a chamber inlet to a chamberoutlet. The hollow chamber has a conical shape adjacent the chamberoutlet that tapers outwardly away from a center axis of the hollowchamber and toward the chamber outlet such that a gas flowing throughthe hollow chamber is directed away from the center axis of the hollowchamber upon being discharged from the chamber outlet.

In this embodiment, the spray device can further comprise a conduitdisposed through and centrally located within the hollow chamber from aconduit inlet to a conduit outlet and receiving the slurry. The conduithas a conical shape adjacent the conduit outlet that tapers outwardlyaway from the center axis of the hollow chamber and toward the conduitoutlet such that the slurry flowing through the conduit is directed awayfrom the center axis of the hollow chamber upon being discharged fromthe conduit outlet.

In this embodiment, the spray device further comprises one or moretarget surfaces disposed in the chamber outlet and secured to theconduit such that a center axis of the one or more target surfaces isoff set from the center axis of the hollow chamber at the chamber outletsuch that the one or more target surfaces direct slurry away from thecenter axis of the one or more target surfaces as the slurry isdischarged from conduit outlet. As slurry is discharged at the conduitoutlet away from the center axis of the one or more target surfaces, thegas flowing through the chamber outlet that is directed away from thecenter axis of the hollow chamber combines with the slurry to form thedroplets. Thus, the gas shapes a plurality of the droplets as thedroplets are formed to provide a uniform distribution of droplets on thecomponent.

In another embodiment of this embodiment of the spray device, one ormore target surfaces are disposed in the chamber outlet and secured tothe conduit such that a center axis of the one or more target surfacesalign with the center axis of the hollow chamber at the chamber outletsuch that the one or more target surfaces direct slurry away from thecenter axis of the one or more target surfaces as the slurry isdischarged from conduit outlet. As slurry is discharged at the conduitoutlet away from the center axis of the one or more target surfaces, thegas flowing through the chamber outlet that is directed away from thecenter axis of the hollow chamber combines with the slurry to form thedroplets. Thus, the gas shapes a plurality of the droplets as thedroplets are formed to provide a uniform distribution of droplets on thecomponent.

In one embodiment, at least one section of the hollow chamber ishelically shaped, extending around the center axis of the hollow chamberto reduce shear forces of air flowing through the hollow chamber priorto the air being discharged from the chamber outlet. In anotherembodiment, at least one section of the conduit is helically shaped,extending around the center axis of the hollow chamber to reduce shearforces of slurry flowing through the conduit prior to being dischargedfrom the chamber outlet.

In one embodiment, the spray device comprises a housing and a hollowchamber disposed through the housing from a chamber inlet to a chamberoutlet and receiving a gas. The chamber outlet has an angled surface toelongate the chamber outlet along an axis perpendicular to the centeraxis of the hollow chamber at the outlet. In this embodiment, the spraydevice further comprises a conduit disposed through and centrallylocated within the hollow chamber from a conduit inlet to a conduitoutlet and receiving the slurry. The conduit outlet also has an angledsurface to elongate the conduit outlet along an axis perpendicular tothe center axis of the hollow chamber at the outlet. The slurry isdischarged at the conduit outlet such that the gas flowing through thechamber outlet is directed toward and combines with the slurry to formthe droplets. Therefore, the gas shapes a plurality of the droplets asthe droplets are formed to provide a uniform distribution of droplets onthe component.

In one embodiment, a system is provided. The system includes a fluidreservoir containing a fluid that promotes evaporation when the fluid isexposed to air and a spray device having a hollow chamber that has aconduit disposed therethrough that is fluidly connected to the firstreservoir to receive a slurry containing the fluid and a mix of ceramicparticles. The fluid reservoir prevents evaporation from the fluid frombeing received within the conduit. The conduit extends from a conduitinlet to a conduit outlet where the slurry is discharged to formdroplets containing the fluid such that based on a discharged amount offluid in the droplets and the fluid promoting evaporation when the fluidis exposed to air, as the droplets traverse from the spray devicetowards the component the fluid contained in the droplets evaporatesprior to impacting the component.

In one embodiment, the fluid is alcohol.

In one embodiment, the fluid contained in the droplets evaporatesfurther based on slurry temperature at the chamber outlet. As the fluidflows through the spray device, the temperature of the fluid isincreased to promote evaporation of the fluid as the fluid travelstoward the component.

In one embodiment, the fluid reservoir increases the temperature of thefluid to promote evaporation of the fluid as the fluid travels towardthe component. In another embodiment, the fluid reservoir has a fluidoutlet located adjacent a bottom of the fluid reservoir to preventevaporation from the fluid from being received within the conduit.

In this embodiment, the system further comprises a gas reservoircontaining a gas and fluidly connected to a chamber inlet of the hollowchamber such that the hollow chamber receives the gas. The gas flowsthrough the spray device from the chamber inlet to a chamber outlet. Thegas is discharged from the spray device at the chamber outlet to mixwith the slurry discharged from the conduit outlet to form the droplets.

In one embodiment, the gas mixes with the slurry inside the conduitbefore being discharged from the spray device at the chamber outlet. Inanother embodiment, the gas includes at least one of air, nitrogen, orargon.

In one embodiment, a spray device is provided. The spray device has ahousing and one or more hollow chambers disposed through the housingfrom one or more chamber inlets to one or more chamber outlets. The oneor more hollow chambers are configured to direct gas received into theone or more hollow chambers away from the center axis of the hollowchamber upon being discharged from the chamber outlet. A conduit isdisposed through and centrally located within the hollow chamber from aconduit inlet to a conduit outlet and receiving a slurry. The one ormore hollow chambers are also configured to direct gas received into theone or more hollow chambers away from the center axis of the hollowchamber upon being discharged from the chamber outlet.

In one embodiment, the spray device further comprises one or more targetsurfaces disposed in the chamber outlet and secured to the conduit suchthat one or more edges of the one or more target surfaces atomize thegas and slurry flowing past the one or more edges to provide a uniformcoating of a slurry and gas droplet formed by the spray device onto anarticle. In the embodiment, the one or more target surfaces have aconverging shape adjacent the chamber outlet that tapers outwardly awayfrom a center axis of the hollow chamber and toward the chamber outlet.

In one embodiment, the one or more target surfaces are secured to theconduit such that one or more center axes of the one or more targetsurfaces are off set from the center axis of the hollow chamber at thechamber outlet. In another embodiment, the one or more target surfacesare secured to the conduit such that a center axis of the one or moretarget surfaces align with the center axis of the hollow chamber at thechamber outlet. In yet another embodiment, at least one section of thehollow chamber is helically shaped, extending around the center axis ofthe hollow chamber from the inlet to the outlet.

In one embodiment, a method is provided for applying a coating to anarticle.

Steps include supplying a slurry comprising a fluid and ceramicparticles to a spray device and discharging the slurry from the spraydevice to form droplets containing the fluid and the ceramic particlesthat are directed toward the component. As the droplets traverse fromthe spray device toward the component the fluid contained in thedroplets at least partially evaporates prior to the ceramic particlesimpacting the component. In another embodiment, the fluid at leastpartially evaporates prior to the ceramic particles impacting thecomponent. In yet another embodiment, an additional step of increasing atemperature of the slurry prior to discharging the slurry from the spraydevice is provided.

In one embodiment, another spray device is provided. The spray devicehas a housing and a hollow chamber disposed through the housing from achamber inlet to a chamber outlet. The hollow chamber has a conicalshape adjacent the chamber outlet that tapers outwardly away from acenter axis of the hollow chamber and toward the chamber outlet suchthat a gas flowing through the hollow chamber is directed away from thecenter axis of the hollow chamber upon being discharged from the chamberoutlet. A conduit is disposed through and centrally located within thehollow chamber from a conduit inlet to a conduit outlet and receiving aslurry. The conduit has a conical shape adjacent the conduit outlet thattapers outwardly away from the center axis of the hollow chamber andtoward the conduit outlet such that the slurry flowing through theconduit is directed away from the center axis of the hollow chamber uponbeing discharged from the conduit outlet. One or more target surfaces isdisposed in the chamber outlet and secured to the conduit such that anedge of the one or more target surfaces atomize the gas and slurryflowing past the edge to provide a uniform coating of a slurry and gasdroplet formed by the spray device onto a surface of a component.

In one embodiment of the spray device, the one or more target surfacesare secured to the conduit such that a center axis of the one or moretarget surfaces are off set from the center axis of the hollow chamberat the chamber outlet. In another embodiment, the one or more targetsurfaces are secured to the conduit such that a center axis of the oneor more target surfaces align with the center axis of the hollow chamberat the chamber outlet.

In one embodiment, at least one section of the hollow chamber ishelically shaped, extending around the center axis of the hollow chamberto increase a shear force at the edge of the one or more target surfacesto provide a finer atomization of slurry and gas flowing past the edgeof the one or more target surfaces. In another embodiment, at least onesection of the conduit is helically shaped, extending around the centeraxis of the hollow chamber to increase a shear force at the edge of theone or more target surfaces to provide a finer atomization of slurry andgas flowing past the edge of the one or more target surfaces.

In one embodiment, a method of providing a coating to a component isprovided and includes providing a spray device. Slurry comprising afluid and ceramic particles is supplied to the spray device. The slurryis discharged from the spray device to form droplets containing thefluid to impact the component. As the droplets traverse from the spraydevice towards the component the fluid contained in the dropletsevaporates prior to strengthen adhesion of the droplets to the componentcompared to adhesion of the droplet to the component had the fluid inthe droplets not evaporated. In addition, the evaporation of the fluidcontained in the droplets results in a more uniform coating on thecomponent as compared to a coating formed if the fluid had notevaporated from the droplets.

FIG. 22 illustrates a perspective view of another embodiment of anatomizing spray device 2200. FIGS. 23 and 24 illustrate cross-sectionalviews of the atomizing spray device 2200 along line 23-23 shown in FIG.22. The atomizing spray device 2200 represents one or more of the spraydevices described herein, such as the spray device 710 shown in FIG. 5.The spray device 2200 has an outer housing 2202 having a hollow chamber2204 disposed therethrough. The hollow chamber 2204 extends through thehousing 2202 from plural different or separate chamber inlets 2206, 2208to plural common or mixed chamber outlets 2210, 2212. The differentinlets 2206, 2208 separately receive the different fluid streams thatare mixed to form the slurry. For example, the inlet 2206 can bereferred to as an outer inlet 2206 and the inlet 2208 can be referred toas an inner inlet 2208 as the inlet 2206 partially or completelyencircles the inlet 2208. In one embodiment, the outer inlet 2206receives a first fluid (e.g., air, argon, nitrogen, or another gas) andthe inner inlet 2208 receives a different, second fluid (e.g., ceramicparticles disposed within a fluid such as an alcohol or water).Alternatively, the inner inlet 2208 receives the ceramic-based fluid andthe outer inlet 2206 receives the other fluid. The fluids may bereceived via conduits connected to pumps.

The chamber 2204 is shaped to keep the fluids received via the differentinlets 2206, 2208 separate in an inlet segment or stage 2214 (shown inFIG. 24) of the housing 2202. The chamber 2204 is shaped so that thefluids received via the different inlets 2206, 2208 merge together andare mixed in a mixing segment or stage 2216 (shown in FIG. 24) of thehousing 2202. The chamber 2204 is shaped to separate the mixture of thefluids into plural separate streams that are ejected from the housing2202 via plural different or separate outlets or orifices 2210, 2212 inan output segment or stage 2218 (shown in FIG. 24) of the housing 2202.In this way, the chamber 2204 extends from the inlets 2206, 2208 to theoutlets 2210, 2212 through the stages 2214, 2216, 2218. The shape of thechamber 2204 separately receives the different fluids, mixes the fluidsinside the housing 2202, and sprays the mixed fluids out of the housing2202 via the outlets 2218 so that the mixed fluids are sprayed onto acomponent, such as a thermal barrier coating of a turbine engine.

In the illustrated embodiment, the outlets 2210, 2212 of the housing2202 are oppositely oriented. For example, the outlets 2210, 2212 faceopposite directions such that the mixed fluids are sprayed from thehousing 2202 in opposite directions. This directs the droplets formed bythe mixed fluids in different directions and onto different portions ofa component to which the additive is being applied. Alternatively, thehousing 2202 may include a greater number of outlets 2210, 2212, only asingle outlet 2210 or 2212, or outlets 2210, 2212 that face indifferent, but not opposite, directions.

As shown in FIGS. 23 and 24, the portions of the chamber 2204 that carrythe fluids in the inlet stage 2214 are larger (e.g., have largerdiameters) than the portions of the chamber 2204 in the outlet stage2218 so that the fluids accelerate during movement through the housing2202 in the chamber 2204 as the fluids are pumped or otherwise forcedinto the housing 2202 via the inlets 2206, 2208.

During operation of the spray device 2200, the fluid such as air,nitrogen, argon, or the like, is pumped into the chamber 2204 via theouter inlet 2206 by a pump (not shown) while another fluid, such asalcohol or water, having ceramic particles therein, is pumped into thechamber 2204 by a pump (not shown) via the inner inlet 2208. The fluidsmix inside the mixing segment 2216 of the chamber 2204, and are forcedthrough the chamber 2204 toward the outlets 2210, 2212. The mixed fluidsare discharged from the housing 2202 via the outlets 2210, 2212 and formtwo-phase droplets. As these droplets travel toward the surface of thecomponent, the non-ceramic-based fluid evaporates, thereby leaving theceramic particles to provide a uniform coating of the surface of thecomponent.

FIG. 25 illustrates a perspective view of another embodiment of anatomizing spray device 2500. FIGS. 26 and 27 illustrate cross-sectionalviews of the atomizing spray device 2500 along line 26-26 shown in FIG.25. The atomizing spray device 2500 represents one or more of the spraydevices described herein, such as the spray device 710 shown in FIG. 5.The spray device 2500 has an outer housing 2502 having a hollow chamber2504 disposed therethrough. The hollow chamber 2504 extends through thehousing 2502 from plural different or separate chamber inlets 2506, 2508to a common or mixed chamber outlet 2518. The different inlets 2506,2508 separately receive the different fluid streams that are mixed toform the slurry. For example, the inlet 2506 can be referred to as anouter inlet 2506 and the inlet 2508 can be referred to as an inner inlet2508 as the inlet 2506 partially or completely encircles the inlet 2508.In one embodiment, the outer inlet 2506 receives a first fluid (e.g.,air, argon, nitrogen, or another gas) and the inner inlet 2508 receivesa different, second fluid (e.g., ceramic particles disposed within afluid such as an alcohol or water). Alternatively, the inner inlet 2508receives the ceramic-based fluid and the outer inlet 2506 receives theother fluid. The fluids may be received via conduits connected to pumps.

The chamber 2504 is shaped to keep the fluids received via the differentinlets 2506, 2508 separate in an inlet segment or stage 2514 of thehousing 2502. The chamber 2504 is shaped so that the fluids received viathe different inlets 2506, 2508 merge together and are mixed in a mixingsegment or stage 2516 of the housing 2502. The chamber 2504 is shaped toseparate the mixture of the fluids into plural separate streams that areejected from the housing 2502 via a single outlet or orifice 2518 in anoutput segment or stage 2520 of the housing 2502. In this way, thechamber 2504 extends from the inlets 2506, 2508 to the outlet 2518through the stages 2514, 2516, 2520. The shape of the chamber 2504separately receives the different fluids, mixes the fluids inside thehousing 2502, and sprays the mixed fluids out of the housing 2502 viathe outlet 2518 so that the mixed fluids are sprayed onto a component,such as a thermal barrier coating of a turbine engine. In theillustrated embodiment, the housing 2502 includes a single outletthrough which the mixed fluid is discharged from the housing 2502.Alternatively, the housing 2502 may include a greater number of outlets2518.

As shown in FIGS. 26 and 27, the portions of the chamber 2504 that carrythe fluids in the inlet stage 2514 are larger (e.g., have largerdiameters) than the portions of the chamber 2504 in the outlet stage2520 so that the fluids accelerate during movement through the housing2502 in the chamber 2504 as the fluids are pumped or otherwise forcedinto the housing 2502 via the inlets 2506, 2508.

During operation of the spray device 2500, the fluid such as air,nitrogen, argon, or the like, is pumped into the chamber 2504 via theouter inlet 2506 by a pump (not shown) while another fluid, such asalcohol or water, having ceramic particles therein, is pumped into thechamber 2504 by a pump (not shown) via the inner inlet 2508. The fluidsmix inside the mixing segment 2516 of the chamber 2504, and are forcedthrough the chamber 2504 toward the outlets 2518. The mixed fluids aredischarged from the housing 2502 via the outlets 2518 and form two-phasedroplets. As these droplets travel toward the surface of the component,the non-ceramic-based fluid evaporates, thereby leaving the ceramicparticles to provide a uniform coating of the surface of the component.

In the embodiments of the spray devices 2200, 2500 shown in FIGS. 22through 27, the droplets formed by the mixed fluids are directed out ofthe housings 2202, 2502 along directions that are transverse (orperpendicular) to a direction in which the fluids are received into theinlets of the housings 2202, 2502. For example, the housing 2202receives the fluids along directions 2222, 2224 (shown in FIG. 22), butsprays the mixed fluid droplets along directions 2226, 2228 (shown inFIG. 22) that are generally (at least 40%), predominantly (at least50%), or substantially (at least 90%) perpendicular to the directions2222, 2224 in one embodiment. The housing 2502 receives the fluids alongdirections 2522, 2524 (shown in FIG. 25), but sprays the mixed fluiddroplets along directions 2526 (shown in FIG. 25) that are generally (atleast 40%), predominantly (at least 50%), or substantially (at least90%) perpendicular to the directions 2522, 2524 in one embodiment.

FIG. 28 illustrates a perspective view of another embodiment of anatomizing spray device 2800. FIGS. 29 and 30 illustrate cross-sectionalviews of the atomizing spray device 2800 along line 29-29 shown in FIG.28. The atomizing spray device 2800 represents one or more of the spraydevices described herein, such as the spray device 710 shown in FIG. 5.The spray device 2800 has an outer housing 2802 having a hollow chamber2804 disposed therethrough. The hollow chamber 2804 extends through thehousing 2802 from plural different or separate chamber inlets 2806, 2808(shown in FIGS. 29 and 30) to a common or mixed chamber outlet 2818. Thedifferent inlets 2806, 2808 separately receive the different fluidstreams that are mixed to form the slurry. For example, the inlet 2806can be referred to as an outer inlet 2806 and the inlet 2808 can bereferred to as an inner inlet 2808 as the inlet 2806 partially orcompletely encircles the inlet 2808. In one embodiment, the outer inlet2806 receives a first fluid (e.g., air, argon, nitrogen, or another gas)and the inner inlet 2808 receives a different, second fluid (e.g.,ceramic particles disposed within a fluid such as an alcohol or water).Alternatively, the inner inlet 2808 receives the ceramic-based fluid andthe outer inlet 2806 receives the other fluid. The fluids may bereceived via conduits connected to pumps.

The chamber 2804 is shaped to keep the fluids received via the differentinlets 2806, 2808 separate in an inlet segment or stage 2814 of thehousing 2802. The chamber 2804 is shaped so that the fluids received viathe different inlets 2806, 2808 merge together and are mixed in a mixingsegment or stage 2816 of the housing 2802. The chamber 2804 is shaped toseparate the mixture of the fluids into plural separate streams that areejected from the housing 2802 via a single outlet or orifice 2818 in anoutput segment or stage 2820 of the housing 2802. In this way, thechamber 2804 extends from the inlets 2806, 2808 to the outlets 2818through the stages 2814, 2816, 2820. The shape of the chamber 2804separately receives the different fluids, mixes the fluids inside thehousing 2802, and sprays the mixed fluids out of the housing 2802 viathe outlet 2818 so that the mixed fluids are sprayed onto a component,such as a thermal barrier coating of a turbine engine. In theillustrated embodiment, the housing 2802 includes a single outletthrough which the mixed fluid is discharged from the housing 2802.Alternatively, the housing 2802 may include a greater number of outlets2818.

During operation of the spray device 2800, the fluid such as air,nitrogen, argon, or the like, is pumped into the chamber 2804 via theouter inlet 2806 by a pump (not shown) while another fluid, such asalcohol or water, having ceramic particles therein, is pumped into thechamber 2804 by a pump (not shown) via the inner inlet 2808. The fluidsmix inside the mixing segment 2816 of the chamber 2804, and are forcedthrough the chamber 2804 toward the outlets 2818. The mixed fluids aredischarged from the housing 2802 via the outlets 2818 and form two-phasedroplets. As these droplets travel toward the surface of the component,the non-ceramic-based fluid evaporates, thereby leaving the ceramicparticles to provide a uniform coating of the surface of the component.

In the embodiment of the spray device 2800 shown in FIGS. 28 through 30,the droplets formed by the mixed fluids are directed out of the housing2802 along directions that are transverse, but not perpendicular, to adirection in which the fluids are received into the inlets of thehousing 2802. For example, the housing 2802 receives the fluids alongdirections 2822, 2824 (shown in FIG. 28), but sprays the mixed fluiddroplets along directions 2826 (shown in FIG. 28) that are notperpendicular to the directions 2822, 2824 in one embodiment. Thedirections 2826 may be oriented at an acute angle relative to thedirections 2822, 2824.

FIG. 31 illustrates a perspective view of another embodiment of anatomizing spray device 3100. FIGS. 32 and 33 illustrate cross-sectionalviews of the atomizing spray device 3100 along line 32-32 shown in FIG.31. The atomizing spray device 3100 represents one or more of the spraydevices described herein, such as the spray device 710 shown in FIG. 5.The spray device 3100 has an outer housing 3102 having a hollow chamber3104 disposed therethrough. The hollow chamber 3104 extends through thehousing 3102 from plural different or separate chamber inlets 3106, 3108to a common or mixed chamber outlet 3118. The different inlets 3106,3108 separately receive the different fluid streams that are mixed toform the slurry. For example, the inlet 3106 can be referred to as anouter inlet 3106 and the inlet 3108 can be referred to as an inner inlet3108 as the inlet 3106 partially or completely encircles the inlet 3108.In one embodiment, the outer inlet 3106 receives a first fluid (e.g.,air, argon, nitrogen, or another gas) and the inner inlet 3108 receivesa different, second fluid (e.g., ceramic particles disposed within afluid such as an alcohol or water). Alternatively, the inner inlet 3108receives the ceramic-based fluid and the outer inlet 3106 receives theother fluid. The fluids may be received via conduits connected to pumps.

The chamber 3104 is shaped to keep the fluids received via the differentinlets 3106, 3108 separate in an inlet segment or stage 3114 of thehousing 3102. In contrast to the embodiments of the spray devices shownin FIGS. 22 through 30, the chamber 3104 is shaped to keep the differentfluids received via the different inlets 3106, 3108 separate throughouta majority or substantially all (e.g., at least 90% of the total volume)of the chamber 3104. As shown in FIG. 31, the chamber 3104 includes aninlet stage that keeps the fluids separate throughout almost all of thehousing 3102. The chamber 3104 combines the fluids in a mixing segmentor stage 3116 of the housing 3102. In contrast to one or more otherembodiments of the spray devices described herein that mix the fluidsmidway between the inlets and the outlet(s) (e.g., the spray devices2200, 2500, 2800), the spray device 3400 mixes the fluids in a locationthat is closer to the outlet 3418 than the inlets 3406, 3408.

The chamber 3104 is shaped to separate the mixture of the fluids intoplural separate streams that are ejected from the housing 3102 via theoutlet or orifice 3118 in an output segment or stage 3120 of the housing3102. In this way, the chamber 3104 extends from the inlets 3106, 3108to the outlets 3118 through the stages 3114, 3116, 3118. The shape ofthe chamber 3104 separately receives the different fluids, mixes thefluids inside the housing 3102, and sprays the mixed fluids out of thehousing 3102 via the outlet 3118 so that the mixed fluids are sprayedonto a component, such as a thermal barrier coating of a turbine engine.

During operation of the spray device 3100, the fluid such as air,nitrogen, argon, or the like, is pumped into the chamber 3104 via theouter inlet 3106 by a pump (not shown) while another fluid, such asalcohol or water, having ceramic particles therein, is pumped into thechamber 3104 by a pump (not shown) via the inner inlet 3108. The fluidsmix inside the mixing segment 3116 of the chamber 3104, and are forcedthrough the chamber 3104 toward the outlets 3118. The mixed fluids aredischarged from the housing 3102 via the outlets 3118 and form two-phasedroplets. As these droplets travel toward the surface of the component,the non-ceramic-based fluid evaporates, thereby leaving the ceramicparticles to provide a uniform coating of the surface of the component.

In the embodiment of the spray device 3100 shown in FIGS. 31 through 33,the droplets formed by the mixed fluids are directed out of the housing3102 along directions that are transverse, but not perpendicular, to adirection in which the fluids are received into the inlets of thehousing 3102. For example, the housing 3102 receives the fluids alongdirections 3122, 3124 (shown in FIG. 31), but sprays the mixed fluiddroplets along directions 3126 (shown in FIG. 31) that are notperpendicular to the directions 3122, 3124 in one embodiment.

FIG. 34 illustrates a perspective view of another embodiment of anatomizing spray device 3400. FIGS. 35 and 36 illustrate cross-sectionalviews of the atomizing spray device 3400 along line 35-35 shown in FIG.34. The atomizing spray device 3400 represents one or more of the spraydevices described herein, such as the spray device 710 shown in FIG. 5.The spray device 3400 has an outer housing 3402 having a hollow chamber3404 disposed therethrough. The hollow chamber 3404 extends through thehousing 3402 from plural different or separate chamber inlets 3406, 3408to a common or mixed chamber outlet 3418. The different inlets 3406,3408 separately receive the different fluid streams that are mixed toform the slurry. For example, the inlet 3406 can be referred to as anouter inlet 3406 and the inlet 3408 can be referred to as an inner inlet3408 as the inlet 3406 partially or completely encircles the inlet 3408.In one embodiment, the outer inlet 3406 receives a first fluid (e.g.,air, argon, nitrogen, or another gas) and the inner inlet 3408 receivesa different, second fluid (e.g., ceramic particles disposed within afluid such as an alcohol or water). Alternatively, the inner inlet 3408receives the ceramic-based fluid and the outer inlet 3406 receives theother fluid. The fluids may be received via conduits connected to pumps.

The chamber 3404 is shaped to keep the fluids received via the differentinlets 3406, 3408 separate in an inlet segment or stage 3414 of thehousing 3402. In contrast to the embodiments of the spray devices shownin FIGS. 22 through 30, the chamber 3404 has a helical shape throughoutall or at least a portion of the inlet stage 3414, as shown in FIG. 36.For example, a first portion 3430 of the chamber 3404 operates as aconduit for the fluid received via the inlet 3406 and a different,second portion 3432 of the chamber 3404 operates as a conduit for thefluid received via the inlet 3408. The first portion 3430 of the chamber3404 helically wraps around the second portion 3432 of the chamber 304in the inlet stage 3414. This winding of the first portion 3430 of thechamber 3404 can help to mix the ceramic particles within the fluid moreevenly (relative to a non-helically shaped conduit).

The chamber 3404 combines the fluids in a mixing segment or stage 3416of the housing 3402. The chamber 3404 is shaped to eject the mixedfluids from the housing 3402 via the outlet or orifice 3418 in themixing stage 3416 of the housing 3402. The shape of the chamber 3404separately receives the different fluids, mixes the fluids inside thehousing 3402, and sprays the mixed fluids out of the housing 3402 viathe outlet 3418 so that the mixed fluids are sprayed onto a component,such as a thermal barrier coating of a turbine engine.

During operation of the spray device 3400, the fluid such as air,nitrogen, argon, or the like, is pumped into the chamber 3404 via theouter inlet 3406 by a pump (not shown) while another fluid, such asalcohol or water, having ceramic particles therein, is pumped into thechamber 3404 by a pump (not shown) via the inner inlet 3408. The fluidsmix inside the mixing segment 3416 of the chamber 3404, and are forcedthrough the chamber 3404 toward the outlets 3418. The mixed fluids aredischarged from the housing 3402 via the outlets 3418 and form two-phasedroplets. As these droplets travel toward the surface of the component,the non-ceramic-based fluid evaporates, thereby leaving the ceramicparticles to provide a uniform coating of the surface of the component.

In the embodiment of the spray device 3400 shown in FIGS. 34 through 33,the droplets formed by the mixed fluids are directed out of the housing3402 along directions that are transverse, but not perpendicular, to adirection in which the fluids are received into the inlets of thehousing 3402. For example, the housing 3402 receives the fluids alongdirections 3422, 3424 (shown in FIG. 34), but sprays the mixed fluiddroplets along directions 3426 (shown in FIG. 34) that are notperpendicular to the directions 3422, 3424 in one embodiment.

In the embodiments of the atomizing spray devices shown herein, theinlets through which the fluids are received (e.g., the fluid in oneinlet and the fluid mixture of ceramic particles and another fluid orgas in another inlet) are on one side or end of the housings of thespray devices, while the outlets through which the droplets formed by amixture of these fluids are ejected from the spray devices are onadjacent or intersecting side surfaces of the housings. For example, thesurface of the housing through which the droplets are ejected from thehousing intersects the surface of the housing through which the fluidsare received into the housing.

In one embodiment, an atomizing spray device includes a housing havingplural inlets and one or more outlets fluidly coupled with each other byan interior chamber. The inlets include a first inlet shaped to receivea first fluid and a second inlet shaped to receive a slurry of ceramicparticles and a second fluid. The interior chamber in the housing isshaped to mix the first fluid received via the first inlet with theslurry received via the second inlet inside the housing to form amixture in a location between the inlets and the one or more outlets.The interior chamber in the housing also is shaped to direct the mixtureformed inside the housing as droplets outside of the housing via the oneor more outlets such that, based on a discharged amount of the firstfluid in the droplets, the first fluid promotes evaporation of thesecond fluid as the droplets traverse from the housing toward a surfaceof a component.

In one example, the first fluid includes air.

In one example, the inlets are located in a first surface of the housingand the one or more outlets are located in a second surface of thehousing that intersects the first surface.

In one example, the housing includes at least two of the outlets locatedin the housing to direct the mixture in opposite directions out of thehousing.

In one example, the one or more outlets are located in the housing todirect the mixture in at least one direction that is perpendicular to adirection in which the first fluid or the second fluid is received intothe inlets.

In one example, the one or more outlets are located in the housing todirect the mixture in at least one direction that is oriented at anacute angle relative to a direction in which the first fluid or thesecond fluid is received into the inlets.

In one example, the chamber in the housing is shaped to mix the firstfluid and the slurry in a location that is midway between the inlets andthe one or more outlets in the housing.

In one example, the chamber in the housing is shaped to mix the firstfluid and the slurry in a location that is closer to the one or moreoutlets than the inlets.

In one example, the chamber in the housing forms a first conduit portionthat carries the first fluid in the housing and a second conduit portionthat carries the slurry in the housing. The first conduit portion canhelically wind around the exterior of the second conduit portion.

In one example, the first and second inlets define separate openingsinto the chamber in the housing, with the first inlet encircling thesecond inlet at one end of the housing.

In one example, the one or more outlets of the housing are shaped tospray the mixture onto the surface of the component at a standoffdistance of at least two centimeters.

In one embodiment, a method includes receiving a first fluid into ahousing of an atomizing spray device through a first inlet of thehousing, receiving a slurry of ceramic particles and a second fluid intothe housing of the atomizing spray device through a second inlet of thehousing, mixing the first fluid and the slurry in an interior chamber ofthe housing of the atomizing spray device to form a mixture in alocation between the first and second inlets and one or more outlets,and directing the mixture outside of the housing of the atomizing spraydevice as droplets via the one or more outlets such that, based on adischarged amount of the first fluid in the droplets, the first fluidpromotes evaporation of the second fluid as the droplets traverse fromthe housing toward a surface of a component.

In one example, the first fluid includes air.

In one example, the second fluid includes an alcohol.

In one example, directing the mixture outside of the housing includesdirecting the mixture in opposite directions out of the housing.

In one example, mixing the first fluid and the slurry occurs in alocation that is midway between the inlets and the one or more outletsin the housing.

In one embodiment, an atomizing spray device includes a housing havingplural inlets through a first surface of the housing and one or moreoutlets through a different, second surface of the housing. The housingincludes an interior chamber that fluidly couples the inlets with theone or more outlets. The inlets include a first inlet shaped to receivea first fluid and a second inlet shaped to receive a slurry of ceramicparticles and a second fluid. The interior chamber in the housing isshaped to mix the first fluid received via the first inlet with theslurry received via the second inlet inside the housing to form amixture in a location between the inlets and the one or more outlets.The interior chamber in the housing also is shaped to direct the mixtureformed inside the housing as droplets outside of the housing via the oneor more outlets such that, based on a discharged amount of the firstfluid in the droplets, the first fluid promotes evaporation of thesecond fluid as the droplets traverse from the housing toward a surfaceof a component.

In one example, the first fluid includes an alcohol.

In one example, the inlets are located in the first surface of thehousing and the one or more outlets are located in the second surface ofthe housing that intersects the first surface.

In one example, the housing includes at least two of the outlets locatedin the housing to direct the mixture in opposite directions out of thehousing.

In one example, the chamber in the housing forms a first conduit portionthat carries the first fluid in the housing and a second conduit portionthat carries the slurry in the housing. The first conduit portion canhelically wind around the exterior of the second conduit portion.

As used herein, an element or step recited in the singular and proceededwith the word “a” or “an” should be understood as not excluding pluralof said elements or steps, unless such exclusion is explicitly stated.Furthermore, references to “one embodiment” of the presently describedsubject matter are not intended to be interpreted as excluding theexistence of additional embodiments that also incorporate the recitedfeatures. Moreover, unless explicitly stated to the contrary,embodiments “comprising” or “having” an element or a plurality ofelements having a particular property may include additional suchelements not having that property.

It is to be understood that the above description is intended to beillustrative, and not restrictive. For example, the above-describedembodiments (and/or aspects thereof) may be used in combination witheach other. In addition, many modifications may be made to adapt aparticular situation or material to the teachings of the subject matterset forth herein without departing from its scope. While the dimensionsand types of materials described herein are intended to define theparameters of the disclosed subject matter, they are by no meanslimiting and are exemplary embodiments. Many other embodiments will beapparent to those of skill in the art upon reviewing the abovedescription. The scope of the subject matter described herein should,therefore, be determined with reference to the appended claims, alongwith the full scope of equivalents to which such claims are entitled. Inthe appended claims, the terms “including” and “in which” are used asthe plain-English equivalents of the respective terms “comprising” and“wherein.” Moreover, in the following claims, the terms “first,”“second,” and “third,” etc. are used merely as labels, and are notintended to impose numerical requirements on their objects. Further, thelimitations of the following claims are not written inmeans-plus-function format and are not intended to be interpreted basedon 38 U.S.C. § 112(f), unless and until such claim limitations expresslyuse the phrase “means for” followed by a statement of function void offurther structure.

This written description uses examples to disclose several embodimentsof the subject matter set forth herein, including the best mode, andalso to enable a person of ordinary skill in the art to practice theembodiments of disclosed subject matter, including making and using thedevices or systems and performing the methods. The patentable scope ofthe subject matter described herein is defined by the claims, and mayinclude other examples that occur to those of ordinary skill in the art.Such other examples are intended to be within the scope of the claims ifthey have structural elements that do not differ from the literallanguage of the claims, or if they include equivalent structuralelements with insubstantial differences from the literal languages ofthe claims.

What is claimed is:
 1. A method comprising: receiving a first fluid intoa housing of an atomizing spray device through a first inlet of thehousing; receiving a slurry of ceramic particles and a second fluid intothe housing of the atomizing spray device through a second inlet of thehousing; mixing the first fluid and the slurry in an interior chamber ofthe housing of the atomizing spray device to form a mixture in alocation between the first and second inlets and one or more outlets;and directing the mixture outside of the housing of the atomizing spraydevice as droplets via the one or more outlets such that, based on adischarged amount of the first fluid in the droplets, the first fluidpromotes evaporation of the second fluid as the droplets traverse fromthe housing toward a surface of a component wherein the first fluid isreceived by a first conduit defined by a first chamber disposed in thehousing, and the slurry is received by a second conduit defined by asecond chamber disposed in the housing, and wherein the first conduitand the second conduit are both helically shaped about a central axis ofthe interior chamber, with the first chamber of the first conduitextending helically around an exterior of the second chamber of thesecond conduit.
 2. The method of claim 1, wherein the first fluidincludes air.
 3. The method of claim 1, wherein the second fluidincludes an alcohol.
 4. The method of claim 1, wherein directing themixture outside of the housing includes directing the mixture inopposite directions out of the housing.
 5. The method of claim 1,wherein mixing the first fluid and the slurry occurs in a location thatis midway between the inlets and the one or more outlets in the housing.6. The method of claim 1, wherein the slurry comprises at least a liquidand a solid.
 7. The method of claim 1, wherein the mixture is directedin at least one direction that is perpendicular to a direction in whichthe first fluid or the slurry is received.
 8. The method of claim 1,wherein the mixture is directed in at least one direction that isoriented at an acute angle relative to a direction in which the firstfluid or the slurry is received into the inlets.
 9. The method of claim1, wherein the first fluid and the slurry are mixed in a location thatis closer to the one or more outlets than the inlets.
 10. The method ofclaim 1, wherein the mixture is directed through at least one outlet isoval-shaped.
 11. The method of claim 1, further comprising spraying themixture onto the surface of the component at a standoff distance of atleast two centimeters.
 12. A method comprising: receiving, by ahelically shaped first conduit defined by a first chamber disposed in ahousing, a first fluid into the housing of an atomizing spray devicethrough a first inlet of the housing, wherein the first conduit ishelically shaped about a central axis of an interior chamber; receiving,by a helically shaped second conduit defined by a second chamberdisposed in the housing, a slurry of ceramic particles and a secondfluid into the housing of the atomizing spray device through a secondinlet of the housing, the slurry comprising at least a liquid and asolid, wherein the second conduit is helically shaped about the centralaxis of the interior chamber, with the first chamber of the firstconduit extending helically around an exterior of the second chamber ofthe second conduit; mixing the first fluid and the slurry in theinterior chamber of the housing of the atomizing spray device to form amixture in a location between the first and second inlets and one ormore outlets; and directing the mixture outside of the housing of theatomizing spray device as droplets via the one or more outlets suchthat, based on a discharged amount of the first fluid in the droplets,the first fluid promotes evaporation of the second fluid as the dropletstraverse from the housing toward a surface of a component.
 13. Themethod of claim 12, wherein directing the mixture outside of the housingincludes directing the mixture in opposite directions out of thehousing.
 14. The method of claim 12, wherein mixing the first fluid andthe slurry occurs in a location that is midway between the inlets andthe one or more outlets in the housing.
 15. The method of claim 12,wherein the mixture is directed in at least one direction that isperpendicular to a direction in which the first fluid or the slurry isreceived.
 16. The method of claim 12, wherein the mixture is directed inat least one direction that is oriented at an acute angle relative to adirection in which the first fluid or the slurry is received into theinlets.
 17. The method of claim 12, wherein the first fluid and theslurry are mixed in a location that is closer to the one or more outletsthan the inlets.
 18. The method of claim 12, further comprising sprayingthe mixture onto the surface of the component at a standoff distance ofat least two centimeters.